Noise from front diff/ transfer case after gear install

[818Gladiator]

I have developed a front end noise or transfer case noise after installing 5.13 gears on my manual gladiator sport. The shop says the noise is coming from the transfer case and it may have been damaged from not programming jeep to 5.13 gears right away. I have drove 100miles, I did forget to program the jeep after picking it up, but it’s a manual. I did program it now, but I put it in 4WD and drove 10feet before it was programmed and that’s when I noticed the noise. Would this cause transfer case damage like the shop is claiming? It sounds like a clicking noise at low speeds and it starts when you turn the wheels. I’m having a hard time believing it’s the transfer case but maybe there is something I am missing. There was no noise or damage before gears, truck has 12,000 miles. The clicking starts in 4WD when the wheels are turned slightly
I posted this in gear/diff section but maybe this is the right place, just hoping anyone with experience can help, TIA

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[Escape.idiocracy]

You have a manual…. And the shop is claiming ecu update to reflect the gears/tires are what’s doing it… ?‍?

Your transfer case is comprised of gears and chains- unless you have the full auto awd transfer case…. (But I

Well I guess you really need to determine if it’s the differential or the transfer case making the noise. Does the noise change in 2wd, 4-hi, 4-low???
- if the noise does not change when shifting the transfer case I would bet front diff….
I would also bank on front diff since they just did the gears 100 miles ago. Have you been following break in procedures?? A quality shop should have you coming back at 500 miles to dump fluid and re-torque everything…. Will be a great time to inspect.
any chance these are yukon

If this is a rubicon? I wonder if they did not get the plunger seated correctly when re-installing the diff/carrier.

if whatever shop you went to keeps giving you a hard time- check out premier west gears in riverside..

 

[818Gladiator]

The noise starts when you turn the wheel and put it in 4WD. The noise does not change in 4WD HI or 4WD LO. There is no noise whatsoever in 2WD. It’s a Sport, base model , not a rubicon. Revolution Gears, not Yukon. I’m in Woodland Hills in the San Fernando valley, riverside is a bit far. The truck is currently at shop. I’m going to have them put the truck on jack-stands and prove to me that the noise is coming from transfer case. It’s a manual base model, what he is saying is the problem I can’t imagine is the problem. Especially if this started after gear install. I’m not 100% sure how the front axles work on jeeps as I have never looked into it, but I am a capable mechanic and understand how cars/trucks generally work. I just went to a professional to have the gears done as I don’t want to run into issues……….

 

[818Gladiator]

after thinking about it…
YES, the ECU of the truck has a setting inside/ option to change the gear ratio of the differential. However this has no bearing on the actual jeep, as it’s a Base Model Manual 6-speed. There is no TCM. Where would the ECU be sending any signal to?

 

[Chaos Theory]

Dumb question, but they changed both the front and rear differential gears, correct? ...to the same ratio

 

[818Gladiator]

Dumb question, but they changed both the front and rear differential gears, correct? ...to the same ratio

They were handed 2 5.13 gears and install kit for front and rear. I however had that same thought

 

[818Gladiator]

There is oil on the front diff and my alignment is off like they removed the front track bar, there is evidence they did something to the front

 

[818Gladiator]

Update:
After texting back and forth with shop. I had to tell them that I have taken tech classes at an FCA certified school, sent him my professors phone number and a news article on my professor. They have taken responsibility and agreed that something is wrong with the install. I should not have had to disclose this information. Mechanics is not my profession, I learn for fun.
If I didn’t have this in my back pocket, I might be screwed. How would a less knowledgeable person be in this situation.

 

[818Gladiator]

I will definitely just buy the tools and do my locker or lsd upgrades myself. Lesson learned.

 

[coastiej171]

Just wondering if anything is related to the (FAD) front axle disconnect? Or a vacuum line for 4WD? I can’t recall the part (maybe 4WD actuator), but when I had an F150 I had a weird noise coming from front end. I had a razor thin cut in a vacuum line that was only seen when wheel was at full turn in one direction, otherwise the vacuum hose looked completely fine with wheels straight. The noise and clunking only happened with 4wd engaged when the actuator had a vacuum to take out of 2wd. I’m just throwing ideas or things to check. Not sure if our 4wd on solid axles on JTs and my old issue with a F150 correlate in any way. Hope you can get your issue fixed and it’s not a grenaded diff

 

[Rusty PW]

No vacuum lines. It's all canbus.

 

[818Gladiator]

Just wondering if anything is related to the (FAD) front axle disconnect? Or a vacuum line for 4WD? I can’t recall the part (maybe 4WD actuator), but when I had an F150 I had a weird noise coming from front end. I had a razor thin cut in a vacuum line that was only seen when wheel was at full turn in one direction, otherwise the vacuum hose looked completely fine with wheels straight. The noise and clunking only happened with 4wd engaged when the actuator had a vacuum to take out of 2wd. I’m just throwing ideas or things to check. Not sure if our 4wd on solid axles on JTs and my old issue with a F150 correlate in any way. Hope you can get your issue fixed and it’s not a grenaded diff

I have worked on f-150s own one for my plant nursery, yes they use vacuum to engage the 4WD. The gladiator does not work this way.

 

[818Gladiator]

No vacuum lines. It's all canbus.

I don’t believe the canbus controls the 4WD, I have a 6speed manual jeep, sport. It’s all manually shifted with levers/linkage. There is a sensor on the front diff to let the ECU know if it’s it’s 2wd or 4WD and a gear position sensor also to let ECU know what gear you are in. I don’t think the can controls anything on a manual gladiator

 

[Rusty PW]

I don’t believe the canbus controls the 4WD, I have a 6speed manual jeep, sport. It’s all manually shifted with levers/linkage. There is a sensor on the front diff to let the ECU know if it’s it’s 2wd or 4WD and a gear position sensor also to let ECU know what gear you are in. I don’t think the can controls anything on a manual gladiator

The FAD on the axle. That's your axle disconnect.

 

[818Gladiator]

I appreciate all suggestions, I do think that there may be a problem in the front axle disconnect, or something to do with the axles. The noise starts when turning the wheel and is clicking/popping sound. But the turning of the wheel makes me think that something was NOT put together the right way

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