3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

03 Front end grinding

Old 03-11-2013, 06:54 PM
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03 Front end grinding

My truck started a low speed/low pitch grinding/growling noise from the front end a few months back. The noise only occurs around 10-20mph when accelerating, decelerating, and coasting. Cannot duplicate the noise when up on jack stands either by hand spinning or putting in drive(both 2wd and 4wd). There is no change in the noise or attitude of the truck when driving in 4wd.

Things done so far to solve the problem (all without any success):
-replaced both right and left wheel hub assembly with new Timken's
-replaced both right and left axle U-Joints
-replaced all U-Joints and double cardan cv ball on front driveshaft
-removed front driveshaft and drove around...noise still present
-rear driveshaft U-joints feel solid with no play
-pulled front diff cover and drained fluid..no metal shavings or obvious wear on gears
-hand turning front driveshaft feels normal w no excessive play

The truck just made 200k miles so I was ok with changing out all of the above parts regardless as preventative maintenance...figured one of those steps would have rid me of the noise, but no such luck.

Anyone have any suggestions or experience the same thing?
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Old 03-11-2013, 09:26 PM
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Have you lubed the caliper slides and pins in order to make sure the pads are not binding? I experienced a similar issue with an 03 company truck a few years ago. I put it on a lift and used a stethoscope type device to listen to the front axle gear housing while the wheels were in motion. After a few hours, I found that the pinion bearings and races showed spalling,therefore creating the noise. I believe it was caused by a low fluid condition due to a leaky seal.
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Old 03-11-2013, 10:56 PM
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whoops forgot to ad that to the long list...

yeah i rebuilt all four calipers and made sure the guide pins were moving easy along with the pistons...installed new pads as well cause I originally thought it might be vibrations from the brakes rubbing and causing that brake shield to rattle...

Yeah I was thinking the only thing left might be the differential bearings by the axle seals that are hidden behind that mounting plate...a little worried to pull that out in fear of not getting the backlash on the big gears back correct
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Old 03-16-2013, 04:28 PM
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When you replaced hubs did you replace axle bearings.
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Old 03-17-2013, 12:40 PM
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Are there axle bearings on the front?
I replaced the hub bearings and thought it had the outer differential bearings that sit just inside the pumpkin...
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