I got a clunking noise going forward and reverse just when I give it gas on initial start. Guys at the in laws shop took it apart and the diff has a lot of play in it. Looking to find A used one they say it is a pain in the *** to rebuild it. Going to keep driving it and pray it doesn't crap out. They say that the bigger tires and torsion bar crank which I done 4 yrs ago could have caused it. I did read on the net that 02-05 differentials have problems with premature wear. Anyone out there have one for 02 with 3.55 gears let me know. None in my area, about 300 mile away for nearest one and they want $350 before shipping. Looking for a better price.

 

$350 sounds good.....
lol

It's the diff and not the CV's? Wow, thats amazing. What exactly has too much play in it?

 

What did you move in the "back and forth" motion? Side to side (laterally) or did you turn the diff as if trying to spin it?

 

Inside the front differential. Removed diff cover and drive shaft and easily could turn in a back and forth motion 1/2 inch either way. Could see some wear also.

 

They turned it as trying to spin it. I'm not a mechanic so I am going with what they said. Front uv joint was replaced a month ago because it was trashed and making a bad noise.

 

I don't know about wearing prematurely, I know of two '02 Ram 4.7s with over 250,000 miles on them, original diffs. Were you changing fluids every 30k as they require? The t-bar crank or any "budget boost" does put additional wear on ALL front end components due to the fact that no adjustments are made to compensate for poor angles it creates as a true suspension lift would. But you usually hear of a CV failure, premature ball joint, u-joint and tie rod/end failures a lot more than the actual differential failing.
I'm not a big fan of AAM diffs by any means, give me a Dana any day, but you don't really hear a lot of front diff failures or rears either for that matter unless it's the POS LSD taking out the rear diff.

These are a bi*ch to rebuild or even set gears in if you don't specifically have experience with AAM axles. Guys who can work on them usually have no shortage of work because most shops (including dealers) in their area will farm work out to them on a regular basis...

 

I have replace ball joints, tie rods also the rack. The noise was bothering me so I asked them to put it on lift. The noise is like a clanging noise like a bad uv joint. Put it in gear get on gas and it makes it. Only once until I have to reverse the it does it in reverse just once. Uv's were checked and are fine. They said it could last a long time it's just that when something is wrong I like to get it fixed.

 

Could be a ring and pinion.

 

That's what I'm thinking and the shop guys aren't comfortable setting a ring & pinion in an AAM axle. I think the "rebuild" would be installing a master install kit (bearings, spiders, etc.) and setting a ring & pinion.

Understandable, as I said, they are a b*tch even for someone who's done it but not in an AAM differential...

 

Sorry to hear about it, hopefully you can get it squared away. I have a 3.55 ring & pinion for your front end. Hit me up if you're interested.