Bang Noise

mlg · July 26, 2010

Hi all, just finished a ton of upgrades on the trooper . Front and rear differential upgrade kits ,snorkle, fabricated automotive style tanks straps (mounting tabs broken), steering gear loosiness fix (thanks Lenney), longer bolts for rear trailing arms and boxed in trailing arms ,installed rubber insulators on all skid plates (fixed 90% of all vibration rattles) , and installed muffler from a 885 Harely. Went riding in the Uintas for the weekend a noticed an intermittent bang noise on hard torque situations in 2wd only . Don"t know if it has been there all along and did'nt here it due to the loud exhaust or is a new problem . When I was loading it to come home i noticed the 4wd actuator was making noise like it was trying to move in and out by itsself. I looked closer and found when I had the front diff out, the cheap Chinese electrical connector terminals for the 4wd actuator had pushed partially out of the connector. I pushed the terminals back in, the actuator now working normally . Plan on replacing connector with higher quality connector . I guess I won't know if this fixes the banging noise till next ride.

Lenny · July 26, 2010

Hi all, just finished a ton of upgrades on the trooper . Front and rear differential upgrade kits ,snorkle, fabricated automotive style tanks straps (mounting tabs broken), steering gear loosiness fix (thanks Lenney), longer bolts for rear trailing arms and boxed in trailing arms ,installed rubber insulators on all skid plates (fixed 90% of all vibration rattles) , and installed muffler from a 885 Harely. Went riding in the Uintas for the weekend a noticed an intermittent bang noise on hard torque situations in 2wd only . Don"t know if it has been there all along and did'nt here it due to the loud exhaust or is a new problem . When I was loading it to come home i noticed the 4wd actuator was making noise like it was trying to move in and out by itsself. I looked closer and found when I had the front diff out, the cheap Chinese electrical connector terminals for the 4wd actuator had pushed partially out of the connector. I pushed the terminals back in, the actuator now working normally . Plan on replacing connector with higher quality connector . I guess I won't know if this fixes the banging noise till next ride.

Your welcome. When you had your diffs apart, you could see that the lockout used an internal ring gear that slid over two gears. When the ring was on one gear, the diff is not locked. When the ring is over both gears, it's in lockout. If the cable isn't adjusted correctly it can leave the ring gear partly engaged over the second gear and even though your thinking you might not be locked out you could be. However in turns when the stress on the ring is the greatest, the ring could slip off under pressure which could make a clunk. Lift the wheels off the ground and in nertral play with the adjustment of the cable to get it to fully engage and disengage. Sounds like you did a lot of good things to your Trooper. Look at your clutch and brake pedals. Wiggle them side to side. Mine had a lot of slop and would rattle a lot. I took them apart and put different bushings which got rid of those rattles. What kind of tools do you have to work with. Maybe a lathe and mill. If so, I can tell you how to replace the your ball joints and tighten your heims joints. These are major sources of clunking in front.

Lenny

mlg · July 26, 2010

Your welcome. When you had your diffs apart, you could see that the lockout used an internal ring gear that slid over two gears. When the ring was on one gear, the diff is not locked. When the ring is over both gears, it's in lockout. If the cable isn't adjusted correctly it can leave the ring gear partly engaged over the second gear and even though your thinking you might not be locked out you could be. However in turns when the stress on the ring is the greatest, the ring could slip off under pressure which could make a clunk. Lift the wheels off the ground and in nertral play with the adjustment of the cable to get it to fully engage and disengage. Sounds like you did a lot of good things to your Trooper. Look at your clutch and brake pedals. Wiggle them side to side. Mine had a lot of slop and would rattle a lot. I took them apart and put different bushings which got rid of those rattles. What kind of tools do you have to work with. Maybe a lathe and mill. If so, I can tell you how to replace the your ball joints and tighten your heims joints. These are major sources of clunking in front.

Lenny

Lenny

Thanks for the info I'll recheck diff lock cable adjustment ,my clutch and brake pedals have a ton of movement in them . I don't have a lathe yet ,its on my tool wish list along with a protools tubing bender ,have about eveything else

jamesrulz · July 27, 2010

how can i get those upgrade kits for the front and rear diff?

Lenny · July 27, 2010

how can i get those upgrade kits for the front and rear diff?

I guess I'll have to just go ahead and make of a batch of kits. I'll begin ordering stuff in a day or two. It will still take a little time to put it all together by the time I get everything shipped to me and get the machining part done. I'll post progress.

Lenny