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Front Axle FAD issues 2020 JT Sport S Noise/Clunk/Rotational sounds

stpetejeepermike

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First Name
Michael
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Aug 24, 2021
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Location
St Pete Florida
Vehicle(s)
2020 Gladiator Sport S
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Self Employed
Hey wonder if anyone has had experience with this issue?

Just got it back from the Dealership "15" days later. Mostly waiting in the parts. Replaced the FAD, Shafts and control module. Within in 8 miles it started again. And its going back after work today.

2wd noise from the axle is happening after a clunk once put into Drive.
4H noise disappears drives like it should..
Tried the figure 8 in a Parking lot 4L/4H/2wd still happens to disengage the front axle.

A Star Case was created and dealership was told to replace the FAD,Shafts and module. I know they did not pop the Dif cover to inspect the Pinion. Spider gears. Could the spider gear where the intermit shaft slides into cause slack/slop in the shaft?

I can only find a very small number of JL/GT forum posts where the shaft plastic bushing failed causing the FAD to connect splines on the edge of the coupler...A video of the issue...
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