Driveline clanking popping noise when hot

Have a 2005 Sequoia. 195,000 kilometers. There is a thumping noise along with a heavy metallic popping sound that goes along with wheel speed. I have been under the truck, replaced both front CV axles and lower ball joints, inspected U joints and greased. I am worried its the front differential but again its quiet when cold.

https://www.youtube.com/watch?v=velBil-06gw&ab_channel=ScottSmith

Will pull the front diff drain plug later today to inspect.

** Does not matter if its in 4x4 or 2wd. Throttle input doesn't make the noise go away. Only seems to lessen going around corners at speed. Noise will go away after coming to a complete stop.

 

I would think any damage would show up as metallic bits in the gear oil and it doesn’t matter whether it’s in 4wd or not.

 

Agreed, will report back once I pull the drain plug.

 

Have you checked wheel bearings?

 

... or even dust shields, etc. Look for impacts. If it increases with RPM, it kinda limits the issue to some rotating mass down there.

 

Serviced the front and rear differentials this morning. No abnormal metal chunks on the magnets. Fluid looked good too.

Completely tore apart both front knuckles again as well, nothing abnormal. Just took it for lunch, same deal. Dead quite leaving, hammering away coming back. Of course won't do it while up on the hoist.

The intermittent thing is really throwing me. Highway speeds its dead silent.

Wheel bearings don't have any abnormal play.

 

Will drain the transfer case oil as well.

 

Did you inspect the U-joints off the vehicle or just crawled underneath? I've been tricked before by U-joints that felt fine until I took them off and then found that they had seized bearings.

 

^ carrier bearing while you’re down there.

 

Do you know anyone with a GoPro?

 

No carrier bearing on the Sequoia. Was the first thing I suspected too.

Going to pull the drive shafts off and properly inspect the U Joints.

All really good suggestions guys, thanks again

 

Interesting when suspension is fully extended (on lift) it doesn't present.

Stupid question, but all bushings checked? Stupid shit that could hit things like dust shields on brakes inspected? Any evidence of clearance probs with the front driveshaft or between xfer case and front diff? Did you do a basic push/pull/slap test while up on lift?

 

Thanks shifty, have done this push / pull / rubber mallet test what feels like 10 times now. Driving myself crazy re-checking things I've already checked.

Drained the transfer case, fluid is nice and clean no issues there.

Re-inspected the driveshaft U joints. No play or anything abnormal noticed but have ordered in replacement U joints to service the rear main drive shaft. Will be here tomorrow. This evening I greased the living hell out of the U joints via the grease nipples on all 4 and drove it home. Didn't make the noise on route home but that doesn't mean much...

When it happens, the thumping is noticed in the car. If windows down then you can hear the metal on metal clanking / popping sound echo from the pavement. Sounds like two hammers hitting each other.

 

And it's rhythmic, right? Increasing in-time with RPM, so not a cab mount or something stupid like that?

 

Its in relation to road speed. Mainly prominent between 40km/h and 70km/h. Think of it like you have a rock stuck in your tire.

 

** EDIT NOT FIXED **
It appears U Joints for the rear driveshaft fixed this issue. Haven't heard the noise since replacing the U Joints. The caps of the joints weren't seized but definitely had flat spot.

 

Jinxed it. Just took it for lunch, drove about 50km started making the noise as soon as I pulled into the parking lot.

Very annoying. Not sure what to try next

 

Yeah, it doesn't sound like a u-joint issue to me, but I'm open to being wrong now and again.

Best bet? Maybe solicit the help of a friend who can sit in the bed or drive alongside you and listen for the source. Or better yet, if you have access to one, get a GoPro and mount in various places to see if you can figure out the source location.

If I'm understanding you, it's loudest between 40kmh-70kmh and - correct me if I'm wrong, but it keeps a consistent tempo, and that tempo increases with speed? If yes, that again suggests it's something tied to rotational masses on the vehicle. Like, a brake dust shield striking something. Something embedded in a tire. Worn bearing (wheel bearing; u-joint; carrier bearing; etc.)

We could go back to questions which could potentially rule out some things. Like ...

• Does it happen if 4LO is engaged at your target speed range?
• If you've a save place to test and the skills to test it, does it happen in reverse?
• If you're in the target speed range of 50kmh-60kmh and you tap the brake, does it stop at all, even for a second?
• If you're in the same target speed range, and you suddenly punch the accelerator, does it stop at all, even for a second?
• Do you see any signs of grease slinging in relation to your CV axle boots, like, maybe your CV axle slung its grease and is now shot?
• Do you see any signs of metal-on-metal contact anywhere, while inspecting everything, including front brake dust shields? Like, really inspect well.
• Jack up both fronts. Grab onto and shake things, like the sway bars, tie rod ends, look for loose bolts, inspect cam bolts, etc.?
• Have you checked your rear brakes lately, or applied/disengaged your e-brake several times to force-adjust your rear drums?

Any of the gas/brake questions these could rule out other suspects. Other tips may shed light on the situation.