Outer Limits 4x4 Board

just redid the swivle hubs wheel bearings and diff bearings in my fj40, tightened up the diff and got it running center and took it for a drive. hubs locked all good, in 4wd all good but in 4wd and hubs locked it sounds like the tail shaft is gunna fall out. the tcase locks up and wont go back into 2wd. had to take the tail shaft out to get it to go back into 2wd. span the diff by hand and no load span the tcase by hand and no load. put it up on stands and ran it and no shaking/clunking. it has done this once before and i could not figure it out but it went away.
tail shaft is a little worn (double cardinal joints) and full of grease.
any ideas

Maybe it's a coincidence .. how about your front axle wrap your front DS hiting your crossmember .. ?

And jus twondering ( are only ideas ) are you complete sure that you have the same gearing Front and rear ..? ( R&P )

Try it also removing your rear DS ..

same gear ratio had it running perfect. everything clears and there is no axle wrap. had it up in the air again this arvo and span the f diff up and put the brakes on to creat some load. its coming from the tcase at the front snout. the drivers axle is a little clunky when u turn but quiet when in a straight line. but the sound and vibration is at the tcase.

glad you found it .. !

almost, know where its coming from just dont know what its dooing to creat that noise and vibration.

davidwalton wrote:almost, know where its coming from just dont know what its dooing to creat that noise and vibration.

worn out bearing .. but it's just easy split the t-case ( I suppose you have the BF1A t-case ) and check it ..

like this ..

it has a 34mm idle shatf insted of that smaller one whatever size it is.
I hate pulling it apart done it a few times but i might have to thanks for the help.

It's the old one .. I'm in 38mm but you can keep the split case with 34mm very common here in Panama ..

its not to bad, snaped one in half before with the 350 chev and lockers. had a hard time finding this one at the wrecker, all i could find is ones with the idle shaft half the size. ( thats in melbourne now live on the gold coast)
Might pull the tcase apart this weekend and replace the bearings and see how i go.

davidwalton wrote:Might pull the tcase apart this weekend and replace the bearings and see how i go.

your best bet ..