Clunk!!! Update: Found Metal Bits in rear diff!!!

[chulisohombre]

the chain should move a lil bit but not much.the slack that is taken up is what will cause the chink in the driveline.a lil bit of metal on the magnet is fine on the rear.15 degrees seems like a lot of movement when you put it in gear.sounds like the backlash is too much.maybe the gears are gettin wore out a lil bit.you would have to put a dial indicator on the gears and see what the backlash is.seems a lil loose to me.mine only goes 1/8 inch at the pinion and is set at .008 per 14 bolt spec.i believe 10 bolt is .005 to .009.it should have some movement til the spiders gears lock up,but im still lookin at the chain as being loose in the tc.how far did it move when you pushed on it?you shouldnt be able to move it much.

 

[smier]

I could move the top section of chain quite a bit, the bottom not as much... I'm leaning towards rebuilding the transfer case, been trying to find a good kit with a chain. So you think the rear may be something that can be adjusted? Mind schooling me a bit on how to check it, and what type of dial indicator so I need? The gears looked pretty good to me, but I guess I've been lucky in never having issues like this before...

 

[chulisohombre]

I could move the top section of chain quite a bit, the bottom not as much... I'm leaning towards rebuilding the transfer case, been trying to find a good kit with a chain. So you think the rear may be something that can be adjusted? Mind schooling me a bit on how to check it, and what type of dial indicator so I need? The gears looked pretty good to me, but I guess I've been lucky in never having issues like this before...

you need a magnet dial indicator.it will hold onto the side of the diff and you have to get the dial inbetween the gear teeth and see how much movement inbetween the gears until they hit.you turn the gear until it hits the pinion and you can tell how far the gears are spread apart from the next gear.or you can get some gear marking compound and see if the gears are meshing together correctly that way by reading the pattern.the gears would make noise when driving if they were worn enough.you would hear a distinct howl when accell or decel though.if its worn out enough that its not meshing correctly it will need a new gear set.im still leanin torward a warn chain drive though.

 

[496truck]

Hey smier, what's the condition of the rear brakes? Try adjusting them and see what happens next...

My thought is that you are seeing so much pinion rotation because of a lack of clamping force from the rear brakes, causing more of a clunk than there should be. Not a bad place to start and it doesn't cost you anything but time.

 

[smier]

While I'm 75% sure that I have a problem farther forward, but I know my rear brakes are on their way out... I actually have new shoes and rebuild kits sitting in my basement, i conpletely redid the front brakes, and just have been dragging my feet on doing the rear brakes. Interesting theory, and could be a contributing factor. Maybe I should quit drooling over m1009's and put the new brakes on!!!