ok... so this weekend i worked on the dodge replacing both front hub assemblies, upper and lower ball joints on both sides, and both axle joints... the main reason i replaced all of this besides having 105,000 miles on the truck was because of a popping in the front driver side hub. what i thought was a busted front hub was actually the axle joint being bad. so since i had all of the parts already bought i replaced all of them. well i put the truck back together, drive it around the farm and put it in 4wheel drive to make sure everything works... well, still have a popping/growling noise coming from the front end when the truck is under a load or brake load. so i jack the truck up off the ground completely and put it in 4 low and make a brake load. i determined the noises were coming from the front diff. so i pull the cover, check the ring gear, spider gears, pinion gear and everything looked good. so i started the truck back up, put it in 4 low, and created the brake load again. i was able to hear the noise and feel the growling coming from where the pinion bearing rides. so i pull the axles, the carrier, and the pinion out. both pinion bearings "seem" to be fine along with everything else.... i have no clue what to do now because everything is checking out ok but there is definitely something wrong... anyone have any ideas???

 

If things are coming apart in the front diff you will see metal in the oil and on the magnet.

 

Mannnn Noises like that can fool you.

All the stuff I do, axles are not one of them. But my initial reaction was pinion bearings. But you say they are good.

Check the U Joints in the front shaft. Look for rust in the joint. They my look good but can fool you. The only other thing I can think of is an inner race may be bad.

Wish I could be more help. I do everything else but rears. Even body work and paint.

 

Thanks guys... There wasn't any metal in the oil at all so that made me worry as well that the problem may not be in the front diff.. My next thought was the joints in the front shaft...

Now the kicker question... Would it be cheaper/easier to replace the 3 U-joints or buy a new replacement shaft??

 

I tackled the front drive shaft once, after changing the rear drive shaft U-Joints. What a pain. Couldn't get clearance to get the X out. Neighbor, who works at a national tranny shop, said those joints take a special machine and his shop doesn't even have one. I gave up and bought a new shaft from TX. The $$ difference wasn't worth the hassle to me. I'm shade tree.
Back to evening brew. . .