Quick help: trying to pinpoint clunking near rear diff

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yes, thats the side cover/panel that you can remove. Drain the t-case before you remove it though, otherwise you will get a face full of gear oil on you.

Yes, you can drive with just the front drivedhaft in place and rear drive shaft off. BUT, I believe you got to have your front wheels locked (turn the locking hubs to "locked" on each tire)

Okay, This is where I always get confused. Also, go SLOW when driving at this point..... You should be able to just drive on 4-high and shouldn't cause issue. But, to play it safe, drive slow as if you were in 4x4 on pavement. Not sure what year your Fj40 is and your set up. Mine has the option to pull a Knob labeled "F.D." and it activities four-wheel-drive by pulling vaccum on a diaphragm. Yours might not have it.

Okay, so first try and drive forward or reverse with you just locking your hubs. If it works, cool. Remember go slow (not highway speeds here)

If not, you then need to pull the "F.D." knob. Should drive now. It'll send power to your front driveshafts and axle. If it works, cool.

If you don't have the "F.D". Knob, then does the truck just go? Ha, not familiar with the later style fj40s ; It should go regardless, but if not, switch it to 4 low and see if you can move.

I don't remember if at this point you're officially "4x4". You should be considered only front wheel drive (or 2wd) since your rear is off. But regardless, I wouldn't be cruisin' past 10mph just to play it safe. More on that topic later I guess.

Let us know what you find
 
yes, thats the side cover/panel that you can remove. Drain the t-case before you remove it though, otherwise you will get a face full of gear oil on you.

Yes, you can drive with just the front drivedhaft in place and rear drive shaft off. BUT, I believe you got to have your front wheels locked (turn the locking hubs to "locked" on each tire)

Okay, This is where I always get confused. Also, go SLOW when driving at this point..... You should be able to just drive on 4-high and shouldn't cause issue. But, to play it safe, drive slow as if you were in 4x4 on pavement. Not sure what year your Fj40 is and your set up. Mine has the option to pull a Knob labeled "F.D." and it activities four-wheel-drive by pulling vaccum on a diaphragm. Yours might not have it.

Okay, so first try and drive forward or reverse with you just locking your hubs. If it works, cool. Remember go slow (not highway speeds here)

If not, you then need to pull the "F.D." knob. Should drive now. It'll send power to your front driveshafts and axle. If it works, cool.

If you don't have the "F.D". Knob, then does the truck just go? Ha, not familiar with the later style fj40s ; It should go regardless, but if not, switch it to 4 low and see if you can move.

I don't remember if at this point you're officially "4x4". You should be considered only front wheel drive (or 2wd) since your rear is off. But regardless, I wouldn't be cruisin' past 10mph just to play it safe. More on that topic later I guess.

Let us know what you find
Got it! Baby steps here to save the golden kingdom! Lol
 
with that cover off you will be able to see whats making that clunking noise when you were working dline by hand. If all looks good or you cant see anything unusual it may be in the nose cone, thats why I asked if you were sure the 4wd collar was fully disengaging. By the sound I bet you see it obviously once cover gone.
 
with that cover off you will be able to see whats making that clunking noise when you were working dline by hand. If all looks good or you cant see anything unusual it may be in the nose cone, thats why I asked if you were sure the 4wd collar was fully disengaging. By the sound I bet you see it obviously once cover gone.
Thinking same thing. Stay tuned.
 
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