Engine/Transmission (1994 - 1998) help...grinding noise in front end

[BSchweers]

I have a 1996 Dodge 2500 4x4 that makes a grinding noise when accelerating. It is coming from the axle disconnect on the front axle. It makes the noise only when running in two wheel drive. If I have it in four wheel drive it does not make a grinding noise. Any info is appreciated.

 

[CumminsPower98]

Are you sure it's coming from the axle? The reason I ask is because there is a weakness in the transfer case where a snap ring can fall off or break on the rear output shaft that can cause a grinding sound. I have not had this happen, only read about it some. Just a thought, don't know if that's what's wrong. Have you made sure your vacuum to the front axle is working correctly to keep things in place up there when in 2wd?

 

[pro99]

I have a 1996 Dodge 2500 4x4 that makes a grinding noise when accelerating. It is coming from the axle disconnect on the front axle. It makes the noise only when running in two wheel drive. If I have it in four wheel drive it does not make a grinding noise. Any info is appreciated.

Try removing the two vacuum lines at the front axle on passengers side and see if it still does it. If the concern is gone replace the vacuum switch on top of the t-case but make sure your t-case lever is adjusted right before that.

 

[JDKammin]

There are several things to check. If you know your hub bearings and ball joints are OK, I would pull the four 1/4" bolts that hold the vacuum disconnect to the axle. Be careful when removing the bolts, as I have had a couple break off. After removing the unit from the axle, check to see if the end of each shift fork still has a wear pad. If not, you can buy replacement wear pads. Check to see if the shift collar slides from one axle shaft to the other. There is a bushing inside the end of one of the axles to center it to the other axle. You can start the truck up with the disconnect unit hanging by the vacuum lines and shift the transfer case into 4x4. Watch to see if the fork moves each way. I know you stated no noise in 4x4, but easy check while you have it removed. Also, check all of you u-joints on the front axle shafts.

 

[SDrake]

Anyone -- I assumed that vacuum is not needed to run in 2wd thinking that a spring did that job. If one of the hoses or the diaphram develops a leak would it be noticed when running in 2wd?

 

[CumminsPower98]

vacuum is used to hold the shifter each direction, there is no spring.