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Old 06-15-2012, 04:35 PM   #1
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'99 TJ Rear End Noise - Your Suggestions?

Hey Guys,

Need some help with this. '99 TJ stock. I'm getting a loud grinding noise when turning. It will happen when turning from a dead stop, more noticeable when on an incline. After driving 30 min or somitmwill grind whenever you turn 90 degrees. Jeep has close to 140k miles on it.

I opened the rear d35 and some of the spider gears are missing small pieces. The teeth aren't missing or chipped, but some of the teeth are missing small pieces. I had a similar noise in the front which turned out to be a bad wheel bearing.

I have no idea what the problem is. If the worn spider gears were causing the problem, wouldn't it grind all the time? It would not just be intermittent, would it?

Any thoughts would be appreciated. I'm tred of everyone looking at me when I drive cause my Jeep sounds like garbage

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Old 06-16-2012, 10:16 AM   #2
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Next day bump. I haven't heard any grinding at all today. Anyone have any ideas?

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Old 06-16-2012, 11:48 AM   #3
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It's hard to diagnose your problem without seeing it, or at least a picture, but I wll add this, The spider gears don't spin (inside the differential itself) when you are driving in a straight line, they don't need to. It's only when you are making a turn (right or left) that the spider gears need to spin (inside the diff) to allow for the different amount of travel between the two axles/tires while turning. So it does make sense that if the spider gears are damaged or worn, that you will only hear the noise that you are referring to when you are turning right or left.
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Old 06-17-2012, 07:39 PM   #4
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Hi Guys,

Here is a picture of the rear diff and also a link to a video of the noise I am getting.

It really is hit or miss. There will be times when I'll make tight turns and nothing. Other times I can't drive without the grinding occuring. Any help and suggestions greatly appreciated!
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Old 06-17-2012, 09:10 PM   #5
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From looking at the picture you posted, my first guess is that the thrust washers that go in between the small spider gears & the differential case, got damaged somehow, and ended up getting caught/smashed between the spider gears & the side gears. It looks like you can see pieces of what's left of them still smashed into the side gears. Do you know how to remove the spider & side gears to check & see if the thrust washers are still where they are supposed to be?
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Old 06-17-2012, 09:39 PM   #6
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No, I can't say that I do know what's involved with that. I read through the service manual and it looks pretty complicated working on the differential.
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Old 06-18-2012, 10:01 AM   #7
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Actually, what you see on the side gears is missing pieces from the teeth, not something that was smashed into them. Those are actually small pits where small shards broke off of.
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Old 06-18-2012, 10:48 AM   #8
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OK, but either way I would replace those gears,
This link shows how to remove the pin that holds the spider gears in the diff carrier D-35 Axle Shaft Removal, once you get that pin out and pull the axles out a few inches, you can rotate the spider gears inside the diff carrier so that they can be removed.
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Old 06-18-2012, 01:34 PM   #9
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Thanks for that link. Does doing that in anyway mess with the relationship between the ring and pinion gears? I do not have the tools or the knowledge to correctly realign the pinion and ring gear. Thanks!
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Old 06-18-2012, 01:55 PM   #10
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No, replacing the spider & side gears will NOT change anything (pinion depth or backlash) on the ring and pinion.
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Old 06-18-2012, 02:12 PM   #11
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This quick video/animation might help you to understand (in general) what you will need to do.
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Old 06-18-2012, 02:59 PM   #12
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Thanks for all the help. That video is great. But i do not have an open diff. My d35 has the trac-lok so is the procedure relatively the same? Thanks.
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Old 06-18-2012, 03:30 PM   #13
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Yes, it's the same procedure basically, just put everything back together in the reverse order that it comes apart

There are probably a lot of members that have the parts that you need sitting in a box in their garage, hopefully someone will chime in and offer them to you for cheap, or free. It would save you some money.
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Old 09-01-2012, 12:29 PM   #14
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Quote:
Originally Posted by stjbg01 View Post
'99 TJ stock. I'm getting a loud grinding noise when turning.
I have a '99 stock TJ with the same problem. My diff clutches have just worn out over time (120K on the TJ). Did your grinding noise ever get resolved?

Here is a great article in JP magazine that gives you a good review of the pros/cons of many lockers. Jeep Locker Overview - Jp Magazine

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