Clicking noise front left axle/differential symptom after changing axle assembly

Thanks for the response.

I think you are right.

The axle may not be seated properly (or fully engaged if that's what you mean).

I noticed the axle has a bit lateral play, more than it did on the right side when I replace the axle there.

I am going to take it apart sometime this week, inspect and update you here on the progress. Hopefully the problem does not get worse but the noise has not changed and remained consistent since I changed it over a week ago.

Hi Roy,

To update the situation.
I removed the axle and put in the old one back.

It seated in properly this time.

But unfortunately it did not solve the problem.

I can tell that it minimized the noise a little bit (whining noise while driving upwards 60km).
Also it minimize the noise when turning by hand, and it feels smoother this time.

I looked inside there didn't seem to be anything wrong. The splines look fine.

The bearings look and feel normal/smooth.

Why it is making a whining noise in those upward speeds is really a mystery to me now.

It's different from wheel bearing, but similar.

The noise kind of sounds like it is coming from the differential where it meets the shaft.

Or the noise is coming from rear bearings, but that would be such a great coincidence if that was the case.

The symptom is a humming/whining noise after 60-70km/h.

I do not know if the clicking noise when turning the wheel transfers over into the humming noise.

Also, after swapping the axle the clicking noise is much less pronounced than before.

Thank you for the response Roy, you are the best.

I have already ordered the rear wheel bearings, which are worn out, but I doubt they are responsible since the noise happened right after I changed the axle.

I was wondering whether it is possible for something to have gone wrong in the process of removing the axle? Or if something could have gone wrong after not seating the new axle in properly?

Initially I used a pry bar to try to remove the axle. I applied it directly against the axle using the sub-frame as the support but I noticed the differential was moving a bit as I did.

I am just really wondering how I could have done anything to the carrier bearing as this noise was not present beforehand. On top of that I had added fresh new differential fluid.

Anyhow, thank you again, I will going through that process.

Just to update. I did not yet do full inspection.

But I have made some observations.

For one, the noise has not changed even after a month since it started.
If the problem was something like wheel bearings the sound would have worsened overtime.

Secondly, when I spin the wheel (at the differential) forward fast, there is a clicking noise that comes on and off.
I think this is the source of the noise at higher speeds.

However, when I spin the wheel in reverse it's relatively silent.

Now, the question is, why would the noise come on only when I spin the wheel forward but not in reverse?

My thought is that if it was really a bearing at the differential the noise would be apparent regardless of which direction I would spin it.

So could it still really be a bearing at the differential?

I am really now trying to understand the internals of the differential to understand why the noise would only come up in one direction.

Any ideas?

Thanks again

Okay, after doing more inspection, there is lateral movement (up and down, side to side) in the axle going to the differential.

Which means it is the carrier bearing.

There seems to be an adjuster as well, not sure if that would help.

Looks like I have to now replace the entire differential since it is not possible to replace it from the outside it seems. A kind of horrible design it seems.

Thanks

Hi ASEMASTER6371,

I waited out the problem and found that the cause of the noise was not the differential.
But worn out tires due to a bad alignment.
So it seems as if the noise when spinning the wheel by hand is not the same noise.

I still have a slightly rough the steering wheel while turning (not always smooth), which could be coming from the differential.

So I would say great design in that case? :)

Thanks again for all the help!

Hi ASEMASTER6371,

Thank you. I changed the power steering pump, lines, cooler and did a complete flush (all this due to leaky lines and cooler due to rust), but problem remains. I assume that the only thing left is the bearing on the steering wheel itself (there is some play about a 1/8 when I grab one end and the other of the steering wheel), and the power steering rack. When I turn the wheel at lower speeds (left or right) it feels rough almost like a bearing is bad. There is also a squeaking noise that sounds as if it's coming from the rack. I already replaced all the front suspension components - new front end. I sprayed some lubricant at the rack rubber housing and does not change.