Two unresolved problems?

[JKibby]

My first problem is rear end howl. The rear end was quiet as can be for the first 3,500 miles. Finally found a dealer who took me seriously and replaced the whole rear end at 5,500 miles. Again, the rear end was quiet but only for a few hundred miles. Now with over 10,000 miles it still howls between 60 and 70 mph and goes away when I let off the throttle.



My second problems clutch rattle. I had TSB 06-001-03 performed and although most of the rattle is gone it will still rattle from time to time.



Anyone else with these problems? Are they problems? Any suggestions?



Jim

 

[rbattelle]

For the rattle, it is a big heavy duty transmission... it will never be very quiet.



As for the axles, what are your driving habits on a new axle? Are you breaking them in properly? You're not driving around with 4wd on all the time (which tends to introduce transfer case noise), right?

 

[bighammer]

I have a sort of howl from the rear that I thought was axle related, but I think it's turbo (or muffler) noise. (it changes with the turbo and not speed) It comes on at about 35 or 40 and goes away at about 60mph.

 

[Steve M]

The exhaust makes kind of a whine glass chirp and also a deep cider jug hoot. Sometimes it sounds like gear whine. Mine does it pretty loud at 60mph with the 5th wheel on. It's the turbo singing through the exhaust with the exhaust note. I hope that's all it is on yours too.

 

[bighammer]

Cider jug is a pretty good description.



I do find it annoying sometimes. I like the high pitch turbo noise, but this is different. I'm wondering if an exhaust alteration would make it better or worse.

 

[JKibby]

The rattle is the same rattle I had before they replaced the clutch under TSB 06-001-03 it just does not rattle as much.



The howl is the SAME howl I had before they put in a completely new rear end. It is definitely not the turbo this comes from the rear of the truck between 60 and 70 mph (70 is where it's most noticeable) and goes away without a load (when I let off gas. ) The fluid level complies with AAM specs. The truck has yet to tow anything and has not been abused. I definitely do not drive on paved surfaces in 4WD and have only engaged it once on a dirt road. Even though I was told the second rear end does not require a break in I kept it below 60 for the first 500 mi. Occasionally I step on it to merge with traffic but use moderate acceleration and typically shift between 2,000 - 2,300 rpm.



I guess what I want to know; is there anybody else that has had the clutch replaced and still experiencing the rattle? Both rear ends did NOT howl when new, does anybody else have a howl coming from the rear end? It sounds like there is a freight train following me.

 

[Vaughn MacKenzie]

JKibby do you know if they completely replaced the entire axle assembly or replace the gears, carrier, bearings, etc. ? If they did the latter it could be there is an alignment or machining flaw that puts high stress on one of the gears causing rapid wear and consequent howl. Have you removed the drain plug and checked for metal debris? If it were my truck I'd do a fluid change and remove the cover and look the insides over good to see if anything doesn't look right, wear patterns on teeth, etc.



Vaughn

 

[JKibby]

Originally posted by Vaughn MacKenzie

JKibby do you know if they completely replaced the entire axle assembly or replace the gears, carrier, bearings, etc. ? .



Vaughn

Replaced everything short of the axles and disk brake rotors. I will do that. Thank you for the advice!

 

[JRensel]

About the clutch rattle with the 6 speed, a replacement on a 2004 1 ton of the disc (clutch package 21010030 FP Number 5086406-AB) didnt do the job for me. Still rattles in lower gears with clutch engaged. Peter at Southbend Clutch says to remove the clutch disc and spread out the springs with a hammer and punch. He says send it to him and he will do it pro bono (for free except shipping).



A local dealer says to crimp in the spring holders with the same tools, either way it could prevent the problem. I have driven 4 2004 1 tons and 3 of them made the noise, but not any of the 3/4 tons. I think that was just chance, not some actual difference.



I am going to drive mine for a while then get it fixed even if I have to pay for it myself. My dealer wont do any more, but others might under warrantee, not sure yet.



Keep us posted on your progress.