unknown click/bang noise while off-roading (2 Viewers)

[filly]

Hello, I ran into an issue with my FZJ80. It makes a weird banging noise. At first, I assumed it was my tie rod hitting my control arms while flexing (I have caster plates). I removed my control arms and noticed some hit marks on both the tie rod and the control arms. Since then, I’ve removed the caster plates, hoping the noise would go away, but it hasn’t. Another thing I thought it might be is the bushings, but I checked them, and they don’t seem to be in terrible condition.

Here is a video of the noise.

any help would be gladly appreciated.

 

[NeverFinis]

It sounds like a sharp snapping sound. Metal on Metal.

How are the axle splines at the front drive flanges?

Splines on both drive shafts ok and at the t-case?

I would put grease (or something similar for witness marks) on your tie rod and check for transfer.

 

[mudgudgeon]

Are bolt holes in diff brackets for the front radius arm worn out or elongated? This can cause a clunk/ click when the suspension flexes.

Also check sway bar bushes and bolts.

 

[BILT4ME]

How about some pictures of the front axle from behind the front tires, on the tie rod as well as the front drive shaft?

At first thought, I'm thinking the ends of the tie rod clamps are catching on the control arms, the driveshaft is in backwards and hitting the sway bar.

However, after listening to the video, pretty sure that's a cracked bracket under the steering gear where the crossbar support is welded to the frame. Clean it off and look for cracks.

 

[filly]

It sounds like a sharp snapping sound. Metal on Metal.

How are the axle splines at the front drive flanges?

Splines on both drive shafts ok and at the t-case?

I would put grease (or something similar for witness marks) on your tie rod and check for transfer.

Recently did a birf rebuild / new drive flanges and also took my drive shaft out and while it was out I checked all the splines so I doubt it’s that also the noise only happens when my suspension is cycling not when I press the gas. Thanks for the help tho