I finally got enough miles on my 85 4runner's new engine to play a little bit today on my in-laws farm. Nice assortment of trails, stream crossings, etc. At the end of one trail I turned around in a field, not terribly muddy but no so much grip I was concerned about binding up the front end like you do on dry pavement. I got a distinct clicking/popping noise from the front axle (was in 4 hi at the time). After getting back on pavement I explored this further, the noise occurs whether turning left or right in 4 hi or 4 lo. No noise going straight or during normal street driving, you have to turn the wheel more than 1/2 way to the left or right. The axles have just been rebuilt w/all bearings, birfs looked fine and were serviced. I looked through the fill plug at the spider gears but can't see anything obviously wrong with the 3 gears I can see. I was also making sure there wasn't a locker in there, as it sounds similar to what you would hear when a locker lets one wheel turn faster than the other. It's only when the front end is binding up which is why I'm thinking it's in the diff, but would appreciate any ideas.

 

Sounds like birfield trouble to me, auto or manual hubs? I've been told nothing but about how much the auto hubs like to pop and do all sorts of goofy crap like that.

 

85.... would assume manual. Sure its not your drive shaft knuckles? IDK just a shot in the dark.

 

Auto was an option, I've seen them, not common, but I've seen them.

 

Manual Aisin hubs, cleaned and lubed, I can hear them engaging. I can drive around with the hubs locked in 2hi and I don't hear anything, it's only when things get loaded. Next thing to try if I get a minute here at work is to lock one hub, put it in 4wd and see if I can get it to do it.

 

On a Honda that would be your CV joints..

good luck

 

Yeah, I think I'm gonna go with the left birf. Was able to localize it to the LF after lunch, not many things it could be beyond that. Spider gears would have been a lot more fun as I'd of course have to install a traction aiding device if they were bad I'm interested to see what I missed when I get it pulled down tonight.