ok, so i'm in 2x4 and only when i drive and hit a bump i hear a thump from the front axle on the passenger side when the wheel is turned to the left. i switch cv axles and its the same. in 4x4 it's like driving on dry pavement even though it's on grass, seems like the front axle wants to lock up, but only when turning left or right. if i drive straight ahead it's fine (im thinkin spyder gears)

i took the front differential assembly out, checked for play in the pinion and ring gear and found none. i did find on the outer axle where it inserts onto the intermediate axle had worn bad on the end, and the inside of the intermediate was also worn. all the bearings seem fine, no leaks in the seals, and i checked the ring gear-pinion pattern and it seems good, the pin and spyders are also good.

the one good thing about today is when i read 3.90 stamped on the ring gear (yep i double checked it), i was positive i was running 3.55.
another question. is the 3.90 a lot rarer than the 3.55 and are they worth any money in case i decide to junk it.

 

if you need help with rebuilding a diff. DRIVETRAIN.COM has all the info you need.

 

found the problem or i should say problems. the outer axle bearing on the passenger side was loose. the only place to get one is the dealer because it has a lip on the outside. i replaced this bearing 5 years ago and it was a two piece made in japan (from the dealer also). the new one is one piece and made by timkin in the U.S. it seems to be a far better bearing. i think they may have had some problems with the earlier two piece design. the front driveshaft also was loose so i checked it and two of the joints had nothing but dust in the u-joint cups so i rebuilt it.
just got the diff. back up in place, tomorrow i will attach the front driveshaft and let everyone how it works in case you run into this problem.

 

Cool! Im glad you got it figurd out. That sucks they get cheepy junk from japan. Good old USA MADE! Thats what We like to see!

 

you do not know how bad this sucks! after all that work it worked great, for about 15 minutes. now it's back to the same thing only worse. 2 wheel drive straight ahead or turning is ok. 4x4 straight ahead is ok. 4x4 turning (on grass) fells like i have two different gear ratio's in the front and rear. i can hear and feel the rear tire spinning every few seconds to catch up. it sounds like the front spider gear washers or pin is worn and there floppin around. i checked all of that and i didn't see any play. the ring gear to pinion gear pattern is great even when i apply pressure to the ring gear with a crowbar.
i couldn't find any play in the pinion or carrier bearings.

i should add that i don't have the proper tools for an exact check on the amount of play on the parts, it's just what i can see.

my next question is how long should you wait after buying fire insurance before an ACCIDENTIAL fire.
just kiddin, but i am at a loss on this one.

 

From the sound of it to me almost sounds normal. when trying to turn in 4wd can be different. I know mine may slip a little too on a tight turn in 4wd. But dubble and tripple check everything.

 

there's loud thumps and bangs still comming from the front diff when you turn the wheel in 4x4 crazy, you can feel it through the whole truck, espicially the floor. i hear a thump on the passinger side and sometimes in the center of the diff.
i hate to trash it crazy, it' been the best 4x4 i've ever owned, there's not much stops it off-road, and i spent a lot of time working on it.

 

sounds like something is not set up right to me, might need to check some stuff with a dial indicator...