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77K5. The IronMaiden...9/2 headed for Blazer Bash 20!

jack of all trades build, overland, dunes, rocks, trails
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I have an issue I've been trying to track down, and I believe it to be the 205 front output...it has had a (sounds like) gear rattle in it since I've ran it.
The condition occurs when in 2w or 4w, on road or offroad, hubs unlocked or locked, and this is w/ a doubler (203/205).
This case (round 6 bolt) had a syncro setup in it factory, and I changed it to a nonsyncro so I could run a 32 spline front output. Basically replaced the shaft w/ a new 32 spline and the syncro pieces were replaced w/ non syncro pieces.
I went through both cases before bolting the doubler together and I"m no expert on T/C's but they seemed simple enough to understand and everything seemed fine.



I put things together as pictured in a NP205 diagram.

np205diagram.jpg


looking for some ideas from similar experiences with what seems to be a front output gear rattle?
 
I have a similar issue with my rig. But it only happens to me when I'm in 4wd and I decelerate. As long as I stay on the throttle it's fine. But as soon as I let off, it chatters pretty bad. MiniWally hinted at a front driveshaft that could be out of balance. I have a shaft from HAD in the front but used an offset u-joint at the tcase end. Hoping that lowering the truck and adjusting pinion angle will solve it for me. But curious as to how you end up solving yours
 
my old long slip PTO type splined front shaft from HAD in the Sonoma started to get some play too and would cause some noise but mostly at low speed.
 
nvrenuf said:
Rear driveshaft vibration?
Click to expand...
I'm not positive that its not John:dunno:
I have a hole in the tunnel for the triple sticks, and through that I can be watching the front driveshaft while the truck is in motion and can see the front shaft is turning slightly (due to drivetrain drag) while the hubs are free and the t/c is in 2WD. I suppose it could be the rear as well, but I didn't change anything rear output related in the case? I have single 1410's on each end of each shaft. Appearances of the joints look new still, except for the dirt and dust.
Kert and I both tried troubleshooting it while in Moab in 2011 (the Maiden! voyage for the truck)...it doesn't appear to be destructive, but just an annoyance.

MNorby said:
any play in the outputs?
Click to expand...
Will check those again Matt...the doubler is still on the bench so I will open it up to check things inside again as well.

muddermilitia said:
I have a similar issue with my rig. But it only happens to me when I'm in 4wd and I decelerate. As long as I stay on the throttle it's fine. But as soon as I let off, it chatters pretty bad. MiniWally hinted at a front driveshaft that could be out of balance. I have a shaft from HAD in the front but used an offset u-joint at the tcase end. Hoping that lowering the truck and adjusting pinion angle will solve it for me. But curious as to how you end up solving yours
Click to expand...
We'll find out by the time the hillbilly dunefest comes around!
 
The front output bearing o the 205in my tow rig was loose and was causing similar issues. I pulled it out and inspected it. The bearing hadn't failed, and looked and worked fine, it was just loose. Replaced the bearing and it was solved!
 
seems as though mine is the same in that regard...didn't have to pry it out of the bearing retainer at all....I'll check that too...thanks!
 
I have to replace my output bearings regularly. Front and rear. Rattle like a sumbitch. I had the rear one lockup once, and bring me to a tire dragging stop.

Martin
 
Martin has your rattle been similar to what I described?

"I have an issue I've been trying to track down, and I believe it to be the 205 front output...it has had a (sounds like) gear rattle in it since I've ran it.
The condition occurs when in 2w or 4w, on road or offroad, hubs unlocked or locked, and this is w/ a doubler (203/205)."
 
New output bearings ordered...thanks its worth a shot while its STILL on the bench!
 
What about driving it without the rear shaft?

I had a pretty good rattle/vibration in mine using single 1410's, swapping to a CV type rear driveshaft (last week) fixed mine. Smooth and silent now.

As far as output bearings go, I'd be surprised if they're bad.
 
I'll keep that in mind too John, I do have single 1410's as well, and thanks for the ideas, I'll narrow this down to something yet!
 
I don't know my angle but the shaft was ~35" riding length so it was reasonably steep for a driveshaft. I was able to get my yokes to the correct matching angles with shimming but the vibration never stopped.
 
Dave is this the same vibration we were looking for on the dunes 2 summers ago? If so, id say it sounded more like the bearing martin suggested than a drive line vibration. It was more of a "clunking" imo
 
I think so Adam, its not a vibration issue though, its sounding more like a rattling bearing from others descriptions.
 
Front hubs replace wheel studs
Mount tires/alum wheels
Replace PS pump….flush PS system
Fix 205 front output rattle
Install trans/doubler
Install driveshafts
Install shifters
Customize tarp cover




205 and T400 ready for install.

HPIM4665 (1280x960).jpg

HPIM4666 (1280x960).jpg
 
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