I have grinding sound in the front end, driver side. it happens more when i go in reverse but is happening in forward also. usually when i start from a stop. only in 4 wheel drive. I thought it was a u joint in the front drive shaft, removed shaft but not the problem. Maybe it is the front hub or the locking device inside? Any ides would be greatly appreciated. I dont think it is the axle joints as it dosent happen more or less if i have the steering cranked.

 

Put the front end on jack stands , and rotate all parts to reproduce the noise , then it should be easier to find .
Sounds like brake pads .

 

i used the word grinding but i guess it is more like a slipping popping sort of noise kind of like a binding unbinding noise. definately not brakes. cannot replicate unless the truck is under power. what actually puts these tucks into 4 wheel drive? are the hubs locked permanately? does the locking take place in the pumpkin? thanks for the replies

 

Now it sounds more like an axial u-joint .
There a few things that lock the front axial , the linkage on the transfer case , has a vacuum switch , the hose goes forward to the front axial to the passenger side of the diff. , at that point is a vacuum motor , that moves a shift fork inside the axial , locking it into 4x4 , then the front wheels are always tied to the axial's , some mod with kits to get lockout hubs on , making only the wheel assemblies turn .
Again , putting the front end on jack stands & turning will help , sometimes the u-joints can be bad , but too gummed up to move/wiggle by hand , look for reddish/brown dust coming out of u-joint seals also , a sign that the bearing went dry / rusted / gone .

 

just opened upfront diff to change fluid and everything looks great. next i will check axl u joints. thanks

 

problem found. there is no fluid in the transfer case. 5 mos ago i had the tranny built and my guess is they never put fluid in. ***!!!!!!!!!!!!! there is a 1 year warranty on the work so it should not be a prob. what is involved in rebuilding a transfer case?

 

Rebuilding is not big a deal , the parts came be expensive .
Need to make sure the case did not get damaged ?

 

i did not see any chips of metal. but there is plenty of metal dust in the ounce os so of fluid that came out. so hopefully it is just a rebuild as the work was done at my cousins shop.

 

You should be able to look & tell the difference in color , steel & aluminum .
If not , then use a magnet , you should not be able to pick up , no aluminum wear parts , if there is , then take a close look at case .

 

it has been filled overnight and no apparent leaks. where can the fluid go if not leaking out through case? talkes to tranny guy and they never drained the t case. So i brought it in for warranty. we'll see what happens. i guess it is possible that someone drained it on me.

 

Which truck , 03-05 ?
Its hard to say without seeing , an old leak can be harder to find [ all dried out ] .
It is connected to trans, possibly going into AT .

 

05. when rebuilding a tranny can the t case lose its fluid. he said he never drains the t case so could it have leaked out of a weephole or something? thanks for the replies

 

I have not worked on that yr & mod , so not sure ,
But its my impression that there is a seal at both ends and a vent on top , so it may be hard for it to leak out , but again , I do think that it is possible for it to go through the front [ bad ] seal into the trans .

 

turns out t case is completely shot and dealer will dix under warranty. cant explain why no fluid, no leaks. they figure not filled fully from factory. I might have found a good dealer (seems like it so far). maybe they just need the work that bad. I have never been treated well at dealers for warranty service, they always come up w/******** reasons for not warrantying my trucks. (like you use it for work!!! you plow with it!!!! you tow trailers no warranty!!) John thanks for the info.

 

Great sounds like it will work out OK .