Noise from front diff/ transfer case after gear install

[818Gladiator]

If I had not paid someone to do it. The way I fix things is just to start over, take it apart and retrace your steps. I hope after all the information I sent the shop, this is the step they take

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[818Gladiator]

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

The FAD is controlled by canbus?

 

[818Gladiator]

Do you happen to have more information on this… so the front axle disconnect is controlled by canbus? Would then not programming the gladiator to 5.13 gears before throwing truck into 4WD have cause an issue? I don’t see how that’s the case… i definitely think it could be something related to the FAD but mechanical not ECU related. Unless I am missing something. It’s a sport manual

 

[Badunit]

Programming for the new ratio has nothing to do with the noise nor will it ever cause any noises. I bet it is the front axle disconnect making the noise. I don't know what they might have done wrong but it seems like it is the most likely source, that it is not fully engaging. If the front and rear gear ratios were not the same you would probably notice it binding up in 4wd. I would expect it to be jumpy.

 

[pcrawfordpt]

I have gone through several weird noises since changing to 5:13 gears and 37 inch tires. I reprogrammed my computer to 5:13 at the shop with a Tazer. The first noise I heard was a sloppy/clunky/grinding noise in 4wd that turned out to be a bad install in the front. This was more noticeable when turning. Took a few thousand miles for this to become noticeable. They didn’t get the pinion depth set right and it ruined the gear set. The shop made good on the repair and replaced the gear set. That went away, but there was still some light grind/click/scrubbing noise, and could be the noise you are describing that is a clicking/grinding noise when turning in 4wd. The harder I turned the more noise. This was never fully figured out, but appears to be related to the computer system trying to control the ABS/traction control. Common but not everyone experiences it. More notable in rigs with larger tires and the re-gear. Supposedly you can turn all that off with a Tazer and it goes away, but mine didn’t. Thought it may have been a bad RCV, but the same noise was made when input back in the factory shafts. Lastly it was the FAD noise. However this one only happens in 2wd. There is a plastic bushing in the intermediate shaft that wears down or gets damaged. It allows shaft to slightly engage and the splines on the shaft grind down. There is a TSB out for this. Turning didn’t matter with this issue. I’ll attach a video of that noise (when it gets really bad) in case you ever hear it or things the noise you hear. Good luck!

 

[818Gladiator]

Can anyone lead me to instructions on assembly of the FAD? TIA

 

[pcrawfordpt]

Can anyone lead me to instructions on assembly of the FAD? TIA

Watch the RCV video for install of their FAD shafts. Quick but detailed video. I don’t think this is your issue though. See my previous post.

 

[818Gladiator]

​

I have gone through several weird noises since changing to 5:13 gears and 37 inch tires. I reprogrammed my computer to 5:13 at the shop with a Tazer. The first noise I heard was a sloppy/clunky/grinding noise in 4wd that turned out to be a bad install in the front. This was more noticeable when turning. Took a few thousand miles for this to become noticeable. The shop made good on the repair and replaced the gear set. That went away, but there was still some light grind/click/scrubbing noise, and could be the noise you are describing that is a clicking/grinding noise when turning in 4wd. The harder I turned the more noise. This was never fully figured out, but appears to be related to the computer system trying to control the ABS/traction control. Common but not everyone experiences it. More notable in rigs with larger tires and the re-gear. Supposedly you can turn all that off with a Tazer and it goes away, but mine didn’t. Thought it may have been a bad RCV, but the same noise was made when input back in the factory shafts. Lastly it was the FAD noise. However this one only happens in 2wd. There is a plastic bushing in the intermediate shaft that wears down or gets damaged. It allows shaft to slightly engage and the splines on the shaft grind down. There is a TSB out for this. Turning didn’t matter with this issue. I’ll attach a video of that noise in case you ever hear it or things the noise you hear. Good luck!

I have gone through several weird noises since changing to 5:13 gears and 37 inch tires. I reprogrammed my computer to 5:13 at the shop with a Tazer. The first noise I heard was a sloppy/clunky/grinding noise in 4wd that turned out to be a bad install in the front. This was more noticeable when turning. Took a few thousand miles for this to become noticeable. The shop made good on the repair and replaced the gear set. That went away, but there was still some light grind/click/scrubbing noise, and could be the noise you are describing that is a clicking/grinding noise when turning in 4wd. The harder I turned the more noise. This was never fully figured out, but appears to be related to the computer system trying to control the ABS/traction control. Common but not everyone experiences it. More notable in rigs with larger tires and the re-gear. Supposedly you can turn all that off with a Tazer and it goes away, but mine didn’t. Thought it may have been a bad RCV, but the same noise was made when input back in the factory shafts. Lastly it was the FAD noise. However this one only happens in 2wd. There is a plastic bushing in the intermediate shaft that wears down or gets damaged. It allows shaft to slightly engage and the splines on the shaft grind down. There is a TSB out for this. Turning didn’t matter with this issue. I’ll attach a video of that noise in case you ever hear it or things the noise you hear. Good luck!

the shop did mention that the ABS system/traction control system was doing weird things when they tested on the lift. It’s had to tell from vid, but what you are describing is similar to the issue I am having. There is a very SLIGHT noise if driving straight, but also my jeep makes some noise with all the mods anyways. BUT when you turn the wheel in 4WD a clear poppig/ clicking noise starts and increases with the more steering angle is applied. Yes what you are describing sounds similar to my problem. I have JSCAN and that’s what I used to reprogram

 

[IdahoRubicon]

This is what makes me not want to re-gear my Gladiator.

I had my Bronco re-geared to 4.88s and have been chasing noises and grinding sounds since.
Had 3 different "good" shops into it at this point and it's still nowhere near as quiet as stock was. And probably have $2500 into the regear at this point. It sucks

 

[818Gladiator]

I went to the shop and programmed the correct gear ratio in and measured the tires and input that information with JSCAN. I had previously programmed the truck for the tires just wanted to make sure programming was set in front of the shop so they would be satisfied.

 

[pcrawfordpt]

​

the shop did mention that the ABS system/traction control system was doing weird things when they tested on the lift. It’s had to tell from vid, but what you are describing is similar to the issue I am having. There is a very SLIGHT noise if driving straight, but also my jeep makes some noise with all the mods anyways. BUT when you turn the wheel in 4WD a clear poppig/ clicking noise starts and increases with the more steering angle is applied. Yes what you are describing sounds similar to my problem. I have JSCAN and that’s what I used to reprogram

If you put the Gladiator on a lift and run it in 4wd it will make ton of noises like all hell is breaking lose. That is the computer trying to figure out the ABS and Traction Control. I think that is normal. If not that could be my problem as well, since that’s how it responded on the lift.

 

[818Gladiator]

Also, isn’t the traction control automatically turned off in 4WD LO? The noise is there in 4WD HI or LO

If you put the Gladiator on a lift and run it in 4wd it will make ton of noises like all hell is breaking lose. That is the computer trying to figure out the ABS and Traction Control. I think that is normal. If not that could be my problem as well, since that’s how it responded on the lift.

Yes on the lift the gladiator did a bunch of weird things. However they then put the truck on jack stands and it acted more normal, and then we drove the truck in front of the shop, the traction control did nothing strange. The truck operated normally other then popping/clicking noise, but the traction control was not fighting anything nor was abs unless it would NOT light up on the dash

 

[818Gladiator]

If you put the Gladiator on a lift and run it in 4wd it will make ton of noises like all hell is breaking lose. That is the computer trying to figure out the ABS and Traction Control. I think that is normal. If not that could be my problem as well, since that’s how it responded on the lift.

What you are describing about the pinion depth, sounds like it could be my issue. I will mention that to the shop. They also said they are calling revolution gears to get there input

 

[818Gladiator]

Shop believes that they have found the problem. I have screwed up my front driveshaft, and installing the gears made everything worse and I broke this joint when I put it in 4WD. I do NOT believe this was the shops doing. I drive my Jeep exclusively in sand and snow. BUT I drive it at 10/10s like a rally car, not joking. On my last outing, i de-beaded a front tire and unloaded my jack by mistake at camp, and had to drive about 1 hour back to camp through sand dunes on 3 wheels, at RPM REDLINE to get through some of the dunes. This could not have been good for Jeep. I do NOT have mechanical sympathy

 

[pcrawfordpt]

What you are describing about the pinion depth, sounds like it could be my issue. I will mention that to the shop. They also said they are calling revolution gears to get there input

I also had Revolution gears installed. The rear has been good for about 10k miles now. after the front was replaced, it has been good as well for about 5k miles. I don’t think Revolution Gear is the issue…most likely the install.

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