Replaced Birfield, Still clicking, please help!

[slowgreen]

Hello all.
Had right-sided clicking for a couple years whenever the truck was accelerating. This was in forward or in reverse. It was rapid, like a baseball card in the spokes of a bicycle. But metal sounding. I also had a clunking sound when accelerating into a hard right turn. So I ordered the front axle rebuild kit.

I removed the birfield, repacked with as much moly would fit in there and reinstalled. It continued to click. I went back in and replaced the grease in the bearings using a needle attachment for the grease gun, still clicking. I filled the housing with grease, still clicking.

Ordered a cruiserparts replacement birfield from Ebay for $189. Its from a cv wholesaler in hemingway south carolina. When I got it it was stiff and impossible to manipulate by hand. This was drastically different from the existing birf's which would swivel easily in every direction. Oddly, It was not polished or shiny. I packed it and installed it with new bearings both inner and outer. The truck, with 166k continues to click.

It clicks from the right front tire anytime I accelerate, forward, reverse, straight, turning. I thought the clicking was the steel balls vibrating inside their birfield housing. I thought the new tighter birfield would surely alleviate this.

What on earth could be going on? Should I put the original one back on since it's a toyota part? Should I send it back for a different new one that might be shinier?

Is there something else that could be causing this clicking?

I'm about to drive 6 hours for vacation this weekend and have serious reservations about my front axle locking up and dragging me off the road.

What would you suggest? I'm getting very good at disassembling my front axle.

Thanks!

 

[NerdNoise]

Nothing yet? I'm stumped. I'm kid of at a point in my life where I love the LC but I also love the idea of finding a good and honest shop that can figure this stuff out for me. Good luck.

 

[Sc0-]

Checked wheel bearings for damage?

 

[slowgreen]

Wheel bearings new as of yesterday.

I think the OE Replacement birfield I got was defective despite it's tightness somehow. I have another one coming in the mail that i'll put on.

and yes I'm getting close the just paying someone else to do it for me.

 

[IronCladLou]

It's interesting that you claim the clicking is rapid. Could it be that it is at a rate faster than what the wheel is turning? I would be looking for other possible sources of the noise - especially after the effort you've put into the Birfs. It seems unlikely that you had a bad one and then the replacement was bad also unless there is something inherent in the knuckle/housing contributing to the noise.

 

[wrongway around]

Swap rims right to left drive it for half an hour ,pullover and feel for heat around bearings ,wheels pinions,joint cups d/s slip yokes,even tires themselves.

 

[slowgreen]

UPDATE

Yes the clicking is rapid.
I noticed this morning, pulling into the driveway next to another car that the clicking was present at idle while in either drive or reverse (the sound was reflected off the other car) In neutral, it goes away.

I revved the engine and the clicking immediately picked up pace, before the wheels even made half a rotation. I did this in forward and reverse multiple times. So the clicking seems to be related to the engine speed only when in gear.

It sounds like a bearing without grease.

 

[western flyer]

I revved the engine and the clicking immediately picked up pace, before the wheels even made half a rotation. I did this in forward and reverse multiple times. So the clicking seems to be related to the engine speed only when in gear.

It sounds like a bearing without grease.

Almost impossible that this is associated with the axle or driveshafts, since the clicking rate varies with engine speed and not with axle rotation.

I suggest you look in the engine bay. Check the belt tensioner pulley, fan, etc.

 

[Kernal]

Alternator belts??

 

[jertiffauk]

That would be a bummer if u did all that to find out its something totally different... At least you'll have that pm out of the way and an extra birf! Good luck.

 

[80chrgd]

Did u check the inner index ring in place? Mine came off loose and made the same noise especially around 40 mph.

 

[Pin_Head]

In neutral, it goes away. I revved the engine and the clicking immediately picked up pace, before the wheels even made half a rotation. I did this in forward and reverse multiple times. So the clicking seems to be related to the engine speed only when in gear.

Maybe stripped splines in a drive flange, but you should also notice this as a failure to move or at least a lag until the VC catches up (if you have a VC; you didn't say which year). Check if the drive shaft is rotating when it is making this noise but not moving, (but don't get under the vehicle).

Could be a weird problem with the transmission.