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Discussion Starter #1
When I engage the 4wd the driverside of the front axle starts making a noise. Depending on speed it can be a clunk like something is flopping as the wheel turns or as I speed up it is a grinding noise.

When I disengage 4wd it goes away. It does not make the noise if I just lock the hubs.
Does anyone know what would cause this?
 

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Could be the axle u-joint(s). When you engage 4WD it adds load to the system. When disengaged, even with the hubs locked, then the front axle u-joints, gears, etc. are just coasting, with no load.
 

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Discussion Starter #3
That makes sense. Is there a way to check that? Can you replace the U-Joint bearings or do you have to get a new axle?
 

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The u-joints in the axle can be replaced. You'll need a shop press to do that.
 
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