OK- I give up- time to take it to the forums.
Right now my truck is non-driveable- to the point where I bought a new car.

My truck is a 2005 Dodge Dakota SLT quad cab with a 4.8L V8 with towing package and a 545rfe transmission


In the last 3 months I have replaced:
Both front CV axles
Both calipers/pistons/ rotors/break pads
Both wheel Hub assemblies
Both steering center link tie rod ends
Every u- joint
both rear coil spring shock absorbers
Transmission service flush and fill

I have completely dismounted, and disassembled the front differential-
inspected each gear for wear- not a tooth missing or a groove messed up


This bastard makes a hell of a popping/grinding sound.
Some history:
in 2013 I had my rear differential serviced, flushed and re-filled
Shortly thereafter- I noticed in 4WD mode, that my truck make a grinding/popping sound.
It has steadily gotten worse- anytime this thing goes in reverse, and now anytime it drives at all.
I've replaced everything short of the transmission.

The sound comes from the front- slightly under the driver floor board
It feels like something in the drive train is grinding/ and/or being dragged along. Like I should be missing gear teeth somewhere.

does this sound like a transmission issue? or is this a front differential-complete overhaul? or is it something small and stupid like the motor actuator on my 4wd transfer case.

I am too poor to take it to a mechanic- who is going to do exactly what I do- and start replacing common parts.

I own a tractor jack, a dewalt 20v impact wrench (which is f-ing amazing btw), and 4 jack stands. I do all my own work, because it usually takes about the same time as a mechanic- and the parts are cheaper than paying some dude $120/hr (outside of DC) to do the same thing.

What more can I check? No I am not throwing any codes

HELP!?

- stuck in a parking spot

 

You said all U-joints so you changed the one on the front drive shaft at the front diff rite? What you described sounds just like when my CV between the front drive shaft and the transfer case went bad though. Other than those two, could it be bearings for the pinion on the front diff, bearings on the t-case flange, bearings on the axle shafts for the front diff, or even the wheel bearings.

 

I just replaced the Wheel bearings, and the complete CV axle half shaft- which is actually incredibly cheap (less than 150) and did myself in under 2 hours.


The weird part- it's not a pop- like a CV axle pop. It's that sickening pop sound when gears aren't aligned and then *POP* into place

 

If it makes a noise get it on camera, upload the video to youtube, and link it here so we can hear it.

 

There's the clue. Does it have the limited slip differential? It sure sounds like a problem w/a limited slip diff.

 

Here's a question, does it continue to make the sound in 2WD or just in 4WD?

If only in 4WD it could be in the transfer case. The front output bearings could be going causing your noise. The sound would be pretty much just bellow the driver's seat, which would be more noticeable from the floor board since the seat covers up that part and insulates from sound.