Front Axle Disconnect whirring/grinding

[JeffJ]

Looking for some advice. 2023 JTRD with 450 miles on it. Obviously under warranty.

I have a weird scenario where my FAD makes light grinding noise for a few seconds in a very specific situation. I have to reverse out of my loose gravel driveway. I just pop the truck into 4HI, back into the street and put it back into 2WD. About 1/10 times after I'm in Drive and starting to pull forward the FAD will make this grinding noise for a few seconds.

I can engage/disengage 4HI as often as I want driving down the street in a straight line. No noise.

Is my FAD busted or can this happen due to the combination of reversing uphill, shifting into 2WD and turning to go down the street?

The dealer probably won't be able to reproduce the noise, but I know it's the FAD by comparing with some YouTube videos. I'm likely facing an uphill battle since it'll be "fine" at the dealer.

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[Escape.idiocracy]

I have not had this issue, and haven’t read of many others having it.
Do you plan on bumping tire size up and off roading? Might be worth ditching the headache and going with a solid axle shaft and eliminating the fad all together…..

If not maybe a good video will help at the dealer- grinding I’m sure will show wear soon enough.

 

[Rusty PW]

My thinking it's at the FAD. But it's where the outer shaft and inner shaft connect. It's a known problem.

Top shaft in the picture.

 

[JeffJ]

My thinking it's at the FAD. But it's where the outer shaft and inner shaft connect. It's a known problem.

Top shaft in the picture.

That's what I'm thinking.

 

[JeffJ]

I have not had this issue, and haven’t read of many others having it.
Do you plan on bumping tire size up and off roading? Might be worth ditching the headache and going with a solid axle shaft and eliminating the fad all together…..

If not maybe a good video will help at the dealer- grinding I’m sure will show wear soon enough.

Yeah, I'm about to go 37s and wheel the heck out of this one. RCVs are part of the long term plan. Just not necessarily budgeted today.

 

[Hootbro]

I reported something similar in another thread.

https://www.jeepgladiatorforum.com/...se-issue-coming-out-of-4h.77275/#post-1261988

There is a Star Case bulletin in that thread that talks about the FAD and having replace the intermediate shaft with a kit.

FWIW, mine has stopped doing it but it seems to coincide with warmer temps.

 

[Stan H]

Mine will sometimes do it under load. But only upon slowing down and then turning. If I shift into 4wd without being under load it won't do it. I have 91600 miles the darn thing has always done this. My theory is that the collar under load doesn't completely engage and as soon as the stress comes off it completes the engagement. I hate the FAD and will be eliminating it as well.

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