This is hard to explain, so here is a video:
Today is the first drive of this FJ40 since I've owned it and after a couple laps around the neighborhood with no problems, I pulled out onto the highway. As soon as I got up to maybe 10-15 mph it started this clunking sound, which sounds like it's coming from the transfer case. Naturally I begin to slow down and the clunking slows with my speed but also gets louder and harder. Once I come to a full stop, I can start driving again and the clunking won't return until I get back up to 10-15 mph. The t-case linkage was completely frozen up so it it was stuck in 2H, which is odd but I can't see how it would related.
Both axles have been rebuilt and the noise is definitely not coming from that far down. There is only a rear driveshaft installed right now, and it's new (Tom Woods).
I've disassembled the t-case as much as I can without removing it (inspection covers, front/rear outputs, removed the output shaft/gear) and the output bearings look fine. There is some light hazing on the bearing races and the rollers also look fine. The bearing cages are loose and can be wobbled around, but I'm not sure if that's normal (I can make a video showing all of this if it would help).
Has anyone come across this before?
Today is the first drive of this FJ40 since I've owned it and after a couple laps around the neighborhood with no problems, I pulled out onto the highway. As soon as I got up to maybe 10-15 mph it started this clunking sound, which sounds like it's coming from the transfer case. Naturally I begin to slow down and the clunking slows with my speed but also gets louder and harder. Once I come to a full stop, I can start driving again and the clunking won't return until I get back up to 10-15 mph. The t-case linkage was completely frozen up so it it was stuck in 2H, which is odd but I can't see how it would related.
Both axles have been rebuilt and the noise is definitely not coming from that far down. There is only a rear driveshaft installed right now, and it's new (Tom Woods).
I've disassembled the t-case as much as I can without removing it (inspection covers, front/rear outputs, removed the output shaft/gear) and the output bearings look fine. There is some light hazing on the bearing races and the rollers also look fine. The bearing cages are loose and can be wobbled around, but I'm not sure if that's normal (I can make a video showing all of this if it would help).
Has anyone come across this before?