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Weird clunking in four wheel drive.

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Offline das zuk

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Weird clunking in four wheel drive.
« on: September 18, 2011, 10:06:29 PM »
Hi i just made the conversion from cj7 to samurai and i am not looking back. However i have not a clue what this random sound it when i am in 4wd. It makes the sound when i am locked in 4wd even if i puch in the clutch yet it will not make the sound when i have the tcase in neutral and hubs are locked. im thinking it is more of a transfer case or front drive line problems based on these parameters. I did read that the zukes are notorious for output shafts to be a problem.  Any thoughts, comments, or striaght up step by step repair guide would be much appreciated!!!!! :laugh:
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Offline mrfuelish

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Re: Weird clunking in four wheel drive.
« Reply #1 on: September 18, 2011, 10:35:14 PM »
need to know more? are you on hard ground or in sand? how fast are you going? do your tires look like they have the same side wall give to them (not psi ) how much lift do you have and where?
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1987,1988,1988,1990 samurai's,  1953 m38a1,  1996 x-90,blue.1996 x-90 red.1994 2 door tracker.   only Dead Fish go with the flow.                No Hairy Nosed Wombats were ran over on the trail today.       My ZUK is Xenophobic.
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Offline das zuk

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Re: Weird clunking in four wheel drive.
« Reply #2 on: September 18, 2011, 10:45:31 PM »
made sound on a more hard dirt, gravel, pavement. Speed was first gear in four low. being that it is stock gears on 31s with the turbo diesel i think i was going about 5 miles an hour?. Tires had same psi. i have an 8 inch spoa lift from rocky-road. Story was that yesterday (the day i got it) i ended up helping my friend who got his zuke stuck in neutral at the transfer case so we hooked her up and i pulled him about a mile to the trail head which is basically where he lived. idk if that pertains to the problem just thought i would add that just in case
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Offline Drone637

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Re: Weird clunking in four wheel drive.
« Reply #3 on: September 19, 2011, 03:04:24 PM »
If you pull the front drive line and drive it around in 4wd with the hubs locked do you get the same noise?
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Offline Capt

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Re: Weird clunking in four wheel drive.
« Reply #4 on: September 19, 2011, 04:45:28 PM »
Just from recent experience.......
I had a strange noise when moving real slow from the left rear wheel.
But only with it on the ground, jacked it up,... NO NOISE.....
I thought, Oh Dam, a axle bearing is going !!!
Ordered all the parts including the backing plate upgrade kits.......
Went to start tearing things down....
ONE OF THE BRAKE DRUM MOUNTING BOLTS (4 small bolts in center) WAS NOT TIGHT!!!!
It was snug, but did not "Krack Loose" like the other 3. Tightened it up....Noise GONE!!!

Oh Well....I am now $135.00 light and inventoried up to build a set of spare rear axles to take along !!

CAPT
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Offline das zuk

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Re: Weird clunking in four wheel drive.
« Reply #5 on: September 19, 2011, 09:03:23 PM »
yes it still does it when i have it in 4wd with hubs locked. but when i have hubs locked but tcase in neutral, i wont make that noise.
Capt- dude that seriously sucks BUT at least you now have a spare. if i had an unlimited amount of dough i would buy every part to build a brand new samurai haha spares are good
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