Registry 3FE Owners Check-In (18 Viewers)

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They told me that too, and I was all set to just crank the radio up, then I saw the drive flanges, replaced the worn parts, and no clunks at all. Just my experience.
 
They told me that too, and I was all set to just crank the radio up, then I saw the drive flanges, replaced the worn parts, and no clunks at all. Just my experience.

10-4, I am of a similar mindset, fix rather then live with the slop and clunking. The FJ80 being on the sluggish side already just seems to exasperate that issue/feeling with the clunking.
 
I was having to feather the gas on and off to avoid the banging sensation. You can drive on it but at some point they will strip out all the way and you have to get home with the cdl engaged.
 
Replaced my '91 flanges with '96 flanges and the clunk went away. Actually, ACC in Atlanta did it, couple of years ago for me.
 
Replaced my '91 flanges with '96 flanges and the clunk went away. Actually, ACC in Atlanta did it, couple of years ago for me.

Did the clunk go way by specifically installing new 96' flanges that would have not been remedied by installing new 91-92 flanges?
 
The newer flanges last longer as they are wider. I forget what year they changed them over.
 
The newer flanges last longer as they are wider. I forget what year they changed them over.

So using the newer FZJ80 flanges, say 96' and 97' to be safe would be just a simple swap? if the flanges are bad does that automatically mean that the birfields need to be replaced? or given that I am at 200k it would be prudent regardless.
 
Worn flanges mean worn birfields. Sadly both would need to be replaced.
 
Worn flanges mean worn birfields. Sadly both would need to be replaced.

Sad indeed...lol, I also noticed a low grade hum as well, could the hum be tied to same flange issues?
 
Are the comments below from Curtis on MUD from another thread likely referencing the same drive flange issue that you are describing?


I'm tellin' ya: 91-92 80's clunk. Put it in reverse, "Slam-clunk!" Put it back in drive, "Slam-clunk!" Let off the gas anything other than as gently as possible, "clunk." Get back on the gas, "clunk." Clunk, clunk, clunk, clunk, clunk!

It's generally believed that it's just a result of all the accumulated AWD slop, and, in fact, I'm starting to think the mysterious VC in the later models is there for no other reason than to reduce this.

80 series(91-92): Embrace the clunk.


62 series(88-90): Fear the clunk.

Curtis
All of my 3fe trucks (three of them) clunked until I did the u-joints. Afterward, the clunking went away.
 
All of my 3fe trucks (three of them) clunked until I did the u-joints. Afterward, the clunking went away.

So I guess I may be looking at u joints after the new birfs/flanges.
 
ACC only changed my flanges and it went away. 95-97 flanges are larger and more robust. Its a misleading sound for sure. But if you pop the cap off and get near the flange while some puts it in gear and inches forward, you can actually see the movement and it becomes clear where the clunk is coming from.
 
ACC only changed my flanges and it went away. 95-97 flanges are larger and more robust. Its a misleading sound for sure. But if you pop the cap off and get near the flange while some puts it in gear and inches forward, you can actually see the movement and it becomes clear where the clunk is coming from.

For the cost that is worth a shot. Did you just swap out the 95-97 flange with gasket and reuse the original flange bolts, nuts and washers?
 
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1991 TLC FJ80

Where does the coolant go? No leaks, I just have to continually top off...
Birfields replaced three times...
Great hunting rig!
Love it to death!
 
ACC only changed my flanges and it went away. 95-97 flanges are larger and more robust. Its a misleading sound for sure. But if you pop the cap off and get near the flange while some puts it in gear and inches forward, you can actually see the movement and it becomes clear where the clunk is coming from.

According to Cdan the later model 95-97 flanges will not fit on the 91-92 sorter splined Birfields due to not being able to install the outer snap ring? FJ80 Front differential - replace or rebuild Are you sure ACC didn't replace your Birfs as well?

Update: I touched base with ACC and Dugan advised that I would just need to use a washer (or two) and a bolt to hold the axle in place. I will update again as we get into the repair. Thanks WarWagon for your assistance.
 
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@Shickalee this what you called me about the other day.
Sorry I forgot to call you back.
Was having the 80 towed for a bad starter.
 

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