Manual D44 front hub not locking

[jon705]

Long: (Shorter version below) So I went with the family to pick out a Christmas tree at the local tree farm this week. The owner asks if I have 4wd - "Sure do" is my answer. He tells me I can drive back through the lane but in 2wd I'll almost surely get stuck. We got back to the end of the lane and attempted to turn around - then the fun began! The rear wheels just kept a-spinning. I hung out of the door and watched the front tire do nothing while I blipped the throttle. The driver's side front hub was also making a clacking noise. If I keep the hubs locked and drive in 2wd the driver side hub makes a grinding noise like the brakes are slightly depressed. With a lot of "rocking" we finally made it back to the road. Unfortunately we had to pull a huge tree by hand.

Last year the 4wd worked great. I could shift on the fly in and out of 4wd at speeds up to 40mph without problems. I have not done anything to the transfer case since then except replace the output shaft seals. I can not shift on the fly this year. Could this be due to the bad hub?

If I jack up the front end, roll underneath and spin the front driveshaft the axleshafts turn and the passenger side tire turns fine. The driver's side tire sits motionless and makes the clacking noise I heard while at the tree farm. If I start to spin the driveshaft in one direction and quickly rotate it in the other direction the driver's axleshaft will catch and turn for about one rotation of the driveshaft then go motionless again.

Shorter Driver's side front hub will not lock. I've taken apart the hub to inspect and all parts appear in good shape and spring works fine. Spinning the front driveshaft with the wheels jacked up the passenger side tire spins, driver side tire does not and hub makes a clacking noise like it's not quite engaged. Also, if driving at normal speed with hubs locked but t-case in 2wd the driver side hub makes a grinding noise kinda like the brakes are slightly depressed. While driving with hubs locked and t-case in 4HI there's a rhythmic thumping that increases with acceleration. I'm assuming the hub is the problem and not the t-case. What can I do to fix this?

I've taken apart the hub and can't see any problems. The spring seems to be working fine and the gears appear to be in good shape. What should I be looking for? Let me know if there's any other information needed to help make a recommendation. I need the 4wd - snow's on the way for the entire week!

Thanks in advance!

 

[gearida]

Sounds like something in the front diff.

 

[JoseyWales]

Shouldn't the hub engage when you take the hub cap off? Seems it would be easy to see then if something is preventing it from engaging.

 

[Bronco717274]

If it's not in your lock-out or the u-joint you might have a busted spider gear. If it's an open diff only one tire will spin, try letting someone hold the pass. tire still while you turn the drive shaft see what happens then. If you put to much grease in the lock-out it won't work right the grease will stop it from fully locking in.

 

[pyro fighter]

Sounds like you have a bad diff. That clicking sound is either your hub not locking all the way or you have busted some teeth off you axel. Best way to figure out with out pullin your diff and axels apart is too buy or swap hubs, if still doing the same thing itll be time to get into the diff. Even if its an open diff there should be no clicking sound. Also check the U-joints on the axel you may have shattered that and that is whats click (this would be very rare, but a possibilty).

 

[DirtDonk]

Since you said spring and gears, I'm assuming stock hubs. But since many people leave the big stock spring in when they change to aftermarket hubs, I'll ask...
Is this a stock or aftermarket locking hub?

Paul

 

[jon705]

Since you said spring and gears, I'm assuming stock hubs. But since many people leave the big stock spring in when they change to aftermarket hubs, I'll ask...
Is this a stock or aftermarket locking hub?

Paul

It's a stock hub.

 

[bludorbronc]

are your wheel bearings tite on that side

 

[uncle ray]

yes it could be the hub itself.

i had a similar failure, i heard a loud clicking from the hub, it seems the hub had taken a few too many beatings from a previous owner in it's past running pizza cutters. the splines and lock ring groove inside had suffered damage, not allowing the sliding part to slide out with only spring pressure. in a pinch i had some luck making it work by unbolting the cover plate for the lockout, exposing the innards, i ended up fixing it right later.

 

[mr.n]

Jack up the front, T-case in N

Have someone turn the drive shaft, both tires should turn.
If not, check if the axle shaft u-joints are turning.
If one side wheel turns, and the u-joint that side is good.

Now for the bad side.
Turn the wheel, does the u-joint turn?
No, bad hub or broken axle shaft.
Listen for noise, if any noise from the diff (pumpkin) open it up and look inside. (Hey, it was time for a fluid change anyways )

Still nothing? We'll need some pics.

 

[jon705]

Update

After taking the DS hub apart three times I decided to compare it to the working PS hub. %) I had a heck of a time prying the inner clutch ring out of the DS hub - the PS almost shot out at me. Another difference was the axle shaft sleeve and inner clutch ring came out as a unit on the PS, but the DS separated. I inspected the two DS pieces more closely and noticed the teeth on the axle shaft sleeve are slightly enlarged and will not fully seat in the inner clutch ring. DING DING DING! So I know what the problem is should I just replace these two parts? Should I grind the teeth on the axle shaft sleeve so that it will fully seat in the inner clutch ring?

Now on to the next problem, what caused this?

 

[Robert_L]

Had the same exact thing happen to me, there was enough for a fingernail to catch on them, I used a fine file until I could get them to mate easily, put er back together and am still driving it a year later with no problems. YMMV.
Best to ya,
Robert

 

[jon705]

Had the same exact thing happen to me, there was enough for a fingernail to catch on them, I used a fine file until I could get them to mate easily, put er back together and am still driving it a year later with no problems. YMMV.
Best to ya,
Robert

That's what I wanted to try so it's good to hear that it will work.

Thanks!

 

[DirtDonk]

No reason not to try it at least. I can't think of anything that it could hurt.
Now, for the underlying problem. There might not even be one other than at some times in it's past, the hub was not fully engaged a time or two and did some unplanned modifications to the teeth.
OR, and this is the best time to check it, perhaps your wheel bearings are in need of some help? Or your spindle bearing is worn out and allowing some excessive wobbling of the outer shaft that's putting some extra stress on the lockout?
I don't know if either of those scenarios can cause the trouble you're having. And perhaps it's just a fluke. But, like anything else, while you've got it half apart, might as well check the rest.
Good luck.

Paul

 

[jon705]

OR, and this is the best time to check it, perhaps your wheel bearings are in need of some help? Or your spindle bearing is worn out and allowing some excessive wobbling of the outer shaft that's putting some extra stress on the lockout?
Paul

The outer shaft has a bit of play in it so that may be the cause. Not sure what the acceptable tolerance is. I'll be doing some research on that as well. Hopefully filing down the teeth can be done in an evening. We're supposed to get a lot of ice and snow this week so I need my 4wd back!

 

[DirtDonk]

Probably hard to tell at the outer end of the axle shaft. It's going to move a bit even when it's all perfect since the bearing is farther back (under the ball-joints about) and only the lockout mechanism supports the shaft at the outer end that you see sticking out the spindle.
Try grabbing the u-joint inside the knuckle and check for play there. Shouldn't be much at all at that end.

Paul

 

[jon705]

Success

All is well again with the front hubs. ;D Grinding and filing the teeth worked out fine. Thanks to all that offered advice!