I know it sounds stupid, but it got ya in here didn't it ?
Seriously though... Do the 3rd gens front axles (4 wheel drive) have the same CAD unit the 2nd gens had?
My 4 wheel drive is clunking and it reminds me of those crappy automatic locking hubs on the Ford explorers when they go bad.
Other than that I am leaning towards a bad u joint. Tooooo cold to get under it now. I'm out in this crap enough, I'll wait til it gets at least to 30 degrees out.

 

Front end turns all the time on the 3rd gens no disconnect of any kind. The only thing that disengages is the T-case. My guess would be a u-joint. Mine had about a 1/4" of play on each side when I replaced them. If they are clunking you should be able to see the play in them. Does it clunk all of the time or just when turning? Does it do it only in 4 wheel or both?

 

Only does it in 4 wheel under light to heavy load. Does not matter if the wheels are turned or not. I am glad there is no disconnect, one less thing to break. (however, guess you can't put a limited slip or locker up there then )

 

You can put a locker for sure. Lockers only engage when there is torque being applied to them, not when it's disconnected. I'm getting the front regeared on Monday, but the rears are backordered til the 15th. The shop that's doing it for me quoted me 1/2 the install price for changing the carrier to a full-carrier replacement locker, so as soon as Detroit comes out with some lockers for the 11.5 and front (9.5?) they'll be going in as well.

 

John-Rod Want do you mean regeared ? Are you changing the ring & pinion ? I called Eaton to ask about lockers & was told they have no plans to make a 11.5 E- lock differential to fit our trucks. But ARB is currently working on a air locker with plans for maybe late summer market. I was looking @ these because I do'nt want a full time positive traction. So I'm wanting for the ARB. If you know of some one coming out with a selectable locker would you please pm.

 

Duh, what was I thinking. I was thinking spool.