Front End making noise

[Mikes offroad]

I have got a situation that I am hoping you guys can help me out with. I parked my 74 CJ5 in the shop last winter to do a little work to it. Lengthen the wheel base, rewire it and some chromolly front shafts with a used set of Warn internal hub conversion kit. During this time it was on jack stands with the tires under the deck. Summer comes everything is put back together so that I can take it out for it's maiden voyage. The first time the unit is under load I hear a noise from the front axle and the D/S tire spins then stops and this goes on until I unlock that hub and drive in 3 wheel drive. First thought in my mind blown hub. Get home strip the hubs apart and they look fine, take the diff cover off and I see two broken pins on the front locker. I purchase a new locker from Stan and install it ready to go play again. Next weekend rolls around and the first time the tires are under load the same noise comes back. The front tire will turn then stop and make a noise like the hub blew then the tire will engage again for a full rotation (give or take) then slip again. So back home pull the cover off and all looks fine, then pull the hub apart and all looks fine. It was perfect when I parked it last year, so my question is what the hell could be causing this freaken noise and lack of power to the D/S. I have even taken the hubs and switch them from side to side and the problem is still there on the D/S no matter what hub is on it. Sorry for the long explanation but I think it is needed to try and explain the situation. Any ideas?

[Vinman]

Maybe check the axle splines were they go into the locker, maybe stripped?

[Mikes off road]

Nope I tried that also and the splines are fine. I even went to the point of placing the stock axle shafts back in to see if that changed anything. It did not change a thing. I am starting to pull my hair out. One person told me that maybe the housing is bent but how could that happen over the winter while up on jack stands.

[Vinman]

I assume you already checked the u-joint.

[Mikes off road]

Yup they are fine, I am not sure what to look at anymore.

[esi]

What type of locker are you running? Could it be partially engaged causing the grip then slip?
I'm assuming that you checked your ring and pinion and have them set up within tolerances.

[Mikes off road]

Yes the ring gear is fine the locker is an Aussie drop in style. All that was not changed at all till I heard the noise then I replaced the old Aussie with a new one fron Northridge. The settings are all within what is written in the instructions. I am wondering if there is any chance that the Warn internal style hub conversion kit might be causing the issue. Maybe the next step will be to switch the whole rotor and hub from one side to the other and see if that changes the slipping to the P/S side rather than the D/S. If it does then it would for sure be a problem liked to the hub conversion kit. I guess I will try that this weekend and see what happens. Keep the ideas coming, I think it has to be something real simple that I am overlooking.

[hps4evr]

if you still have the stock differential side gears and spider gears maybe try putting them back in. see what happens. or what should happen is it will act like an open diff again. im wondering if the locker is slipping for some odd reason. flip the side plates on the locker, the teeth grab on the opposite edge, or thats how my lock-rites look. i havent seen an aussie in person.
it does sound odd though. funny noise and one wheel not turning with power. if its locked and you're going in a straight line they should spin together. if you turn then they should unlock.

[morerpmfred]

Had that same problem and it was in the hubs. pull the hub of and check everything. Spring is on the right side of the slider gear. check all the splines for burrs both external and internal. slider gear engaging properly. snap ring in place, hub cams not gummed up with crap. clean it all up and dry test it to make sure slider gear is engaging fully. Any of these things can prevent the slider gear from engaging fully and  then it partially engages and then locks and then unlocks and then internal and external splines get machined of if you want to callmit tha

[morerpmfred]

last line meant to say, if you want to call it that.

[Mikes offroad]

Thanks for the ideas guys, I have eliminated the hubs because I have switch them side for side and the problem is always on the drivers side. Like I stated I even went as far a purchasing a new Aussie locker and the problem is still there. I am starting to think that maybe there is a problem with the actual Warn conversion kit that switches the hubs to an internal style hub. Will keep you posted.

[cLAY]

Couple of questions to clarify.

Is this a new to you Jeep? Is it possible someone installed different ratios front and rear?

When you say the front left wheel spins then stops, do you mean it locks up?

How does it drive in 2wd with the hubs locked?

How does it drive in 4wd with the hubs unlocked?

If you jack both tires up in the air can you spin them by hand? With hubs in?

Did you leave the calipers hanging by the hoses at some time causing an internal kink and causing the brake to stay on?

Some things to think about anyway.....

[morerpmfred]

I wonder if that is Holgers old jeep. it went of to Yellowknife when he sold it. It may have a bunch of ford parts on the spindle/hub assembly.

[Mikes offroad]

Here are some answers to your questions.

1) I have owned the Jeep for three years and it was fine when I pulled it into the shop at the end of last year
2) When in 4wd being that the front is locked both tires will spin then the drivers side and only the drivers side will disengage make a weird noise then it will engage again. This will continue as-long as I am on the throttle.
3) It drives great in 2wd with the hubs locked it only makes the noise under load (climbing a rock face or a sand hill examples)
4)Same as above drives great
5) Yes I can lock the hubs and turn the PS or the DS and the other tire turns no problem. It seems to disengage (only way to explain it) when the front is under a load.
6) It is funny that you mention that one because the caliper seals were leaking so I replaced both calibers with new Russell braided stainless hoses. The new hoses were needed because last year I tore one and replaced it with a rubber one so ordered new for both sides.

Like I said I am starting to think that it is the Warn Internal Hub conversion kit that is used when I installed it. I will switch the hub and rotor side for side and see if the issue moves to the PS or stays on the DS. If it stays on the DS then there has to be an internal issue with the axle. Not sure how that could have happened but will see this weekend.
 No this Jeep came from BC around 10 years ago and I installed a Warn Internal Hub kit  (used) over the winter.

[cLAY]

That sounds like a hub issue to me. Had a similar problem last winter. One wheel would make a loud bang when under load and then slip. Turned out the internal gear in the hub was a bit worn where it engages and would slip/jump teeth.

Check the splines inside the hub and make sure they are good since you've already checked the locking hub.