Thanks guys,

The noise has always sounded like it was coming from the front and in the area of the differential.
I have checked all u-joints and all are good. I have NOT checked fluid levels in either the transmission or the transfer case. I will do that... it does shifts fine..... I live on a Island so my top speed is around 45mph. It makes the noise in all gears. When I put the clutch in the sound doesnt change.  It has been making this sound for a while now (months) but never seriously sounding.... almost like loud tire noise until recently when as I've said it sounds like something is about to give.

Dennis

Any gear with clutch in or out and not related to engine rpms.

Dennis

And does the noise change at all with vehicle speed?
And it does only make the noise when the vehicle is moving, right?

You said earlier that it makes the noise when the tcase is in 2wd and the hubs are set to free.....that eliminates all front drivetrain components (front driveshaft, front third, front axles)....so swapping your diff is not going to get rid of the noise.

Could it be something like the brake pads are wore out?  When they get wore down and start "grinding" into the rotor it will make a very loud rumbling/growling sound.  Check the brake pads and check the rotors to see if they have grooves wore into them or are rough.

What about the brake rotor shield....could it be bent and rubbing against something?

Well it 6 pm here and I just had dinner so it's time to head back out to the shop and work on the Samurai.
I've decided to put every thing back together with new front brake pads and new rotors. I will also be installing the newer 1991 3rd member. Then I'll start from scratch to find this elusive problem.

Thanks again for all the advise.. It's great that you guys would take the time to help me problem solve.
Dennis

Well it 6 pm here and I just had dinner so it's time to head back out to the shop and work on the Samurai.
I've decided to put every thing back together with new front brake pads and new rotors. I will also be installing the newer 1991 3rd member. Then I'll start from scratch to find this elusive problem.

Thanks again for all the advise.. It's great that you guys would take the time to help me problem solve.
Dennis

I wasn't saying that the brakes are what is making the noise....I was just suggesting that would be something to look into.  I hate to see you spend money unnecessarily on them, if they are still in good shape.  But if they are making the noise it should be quite obvious by looking at the pads and/or rotors.

Good luck with whatever you decide to do.  Keep us updated.

Skyhiranger,

No, no, no, I didn't buy the new brake parts because of your suggestion. I had already bought them knowing my rotors have seen a lot of abuse over the past 175,000 miles. I purchased a new setfor 52 bucks delivered so it was a no brainer.
I just finished putting in the newer 3rd member and hooking up the drive shaft.... all went smooth. I then plugged in the axles and turned them by hand. It feels a whole lot smoother even without the gear oil.
I have the transmission in neutral and the transfer case in 2 wheel high.... should the drive shaft coming off the 3rd member be turning as I rotate the axles?

Dennis

Skyhiranger,

No, no, no, I didn't buy the new brake parts because of your suggestion. I had already bought them knowing my rotors have seen a lot of abuse over the past 175,000 miles. I purchased a new setfor 52 bucks delivered so it was a no brainer.
I just finished putting in the newer 3rd member and hooking up the drive shaft.... all went smooth. I then plugged in the axles and turned them by hand. It feels a whole lot smoother even without the gear oil.
I have the transmission in neutral and the transfer case in 2 wheel high.... should the drive shaft coming off the 3rd member be turning as I rotate the axles?

Dennis

Oh ok.
If you turn the axle shaft by hand then it should turn the driveshaft......it doesn't make any difference where your tcase and tranny levers are, since you are "powering" backwards through the drivetrain (if that makes sense).

If you turn the axle shaft by hand then it should turn the driveshaft......it doesn't make any difference where your tcase and tranny levers are, since you are "powering" backwards through the drivetrain (if that makes sense).


Explain please!

I thought of that after I wrote my last post... I feel like a real bonehead I just wasn't thinking. Anyway I will get my new brakes and rotors on tomorrow and give it another road test... I think it could be my transmission.

Thanks for the help,
Dennis