Freewheel Hubs Making a funny noise - IFS

[4x4 Junkie]

Hi Gents,

I have been dreading writing this post at the thought of what the resultant advise might be, but I cannot leave it any longer - it's eating at my nerves.

I have a 2002 3.0 KZ-TE with 250000km on the clock. It is in overall good mechanical condition and has never let me down. During my trip to Limopo and Lesotho in December, I noticed a sound from the freewheel hubs when drive on corrugated roads. It makes a "click" sound. I have heard the same sound before after using the 4WD system when disengaging after a trail or the like.

The fact that I now hear this "disengaging" sound when the system is engaged and when driving gravel/corrugated roads, leaves me to worrying about how to remedy the problem (if it is a problem). I did a quick test at home over the weekend; I jacked the car up and put bokkie stands front and rear - engaged 4H and 4L and the 4WD systems engages fine.

Can someone maybe share some personal insights or mechanical advise on what may be the cause of this and if it is anything to cause concern?

[Blitzkrieg]

Hi Julian,
I removed my SFA's hubs and found that the spring separated from the holding plate.
If you decide to remove the hubs be carefull when removing the cotters (just behind the nuts and washers), a light tap with a hammer on the side of the hub should loosen them up. They are very expensive from Toyota and hard to find.
I have a picture somewhere of the hub when I removed it, will see if I can post it for you.

[Blitzkrieg]

This is the only pic I have, sorry Julian.
Hopefully it's not a major failure.

[4x4Maniac]

Hi Julian, from the description above it doesn't seem to actually disengage, or do I have it wrong?

Have you considered the clicking noise is perhaps from the pads, maybe some Copper grease on the anti-rattle plates so they don't Rattle? Also check all the split pins.

If you need to open the hub and it is the spring inside, the cone washers can be pulled out by hitting the bolts with another bolt and nut screwed on the loose bolt, that way the cone washers will just pop out. Examine the hub spring.

Hope that makes sense...

[4x4 Junkie]

It is definitely not the squeak plates on the brakes that is making the noise, that is very familiar sound and I have changed the brakes many times myself.

From what I could establish, the 4WD system does engage and remains engaged, but I get that clicking sound while driving.

[Blitzkrieg]

Is the clicking sound only present in 4x4 engaged?

[4x4Maniac]

Does it make a clicking sound when going straight or more prominently when turning whilst in 4x4? Could it perhaps be the inner CV's if going straight or outer CV's when turning... Otherwise what about wheel bearings? I can't think anything is wrong with the hubs, it's a simple has a simple function. It connects the wheel hub with the splines of the stub axle, which is connected to the front diff, so it has to be either CV's or inside the diff.

[Blitzkrieg]

I also suspect wheel bearings, then it should make that sound even in 2x4.
If you decide to replace wheel bearings I suggeset Timken.
A quick check to do is lift up the front wheels and check end play.

[Pietman]

Hi Julian

Are you sure it is the front hubs that are making the noise and not your front diff?

I had my front diff making almost the same sound, only when 4x4 was engaged. End result was front pinion had 3 pins broken off.

But hopefully yours is not the same.

Regards
Pieter

[4x4 Junkie]

I have heard the sound when in 2x4. I really hope it's no diff related. Then we're talking serious $$$$ ... and out the window goes my theory that Hilux's are cheap to maintain

[Pietman]

If you have heard the sound in 2x4 you can count diff related problems out. The front diff I think will only be noisy when 4x4 is engaged. That was my problem. Everytime I engaged 4x4 the ticking sound would start... Like a timebomb

[4x4 Junkie]

Maybe it could then be wheel bearings or the hubs. I checked out some video tutorials on youtube over the weekend, doesn't seem to difficult to clean and service. My lux is in this week to get some cosmetics done. I'll tackle the front axle next weekend.

[Pietman]

Good luck, i will hold thumbs for you

[george]

My hubs are also doing the clicking sound when disengaged. :alvarin: For now I drive with the hubs in the lock position and the sound is gone. Hoppy can sort it out when I am back Lets hope it last to then

[ForYota]

Julian, i had the same thing when 4wd engaged in low. When i turned to the right it sounded exactly like a worn cv... I also knew that my wheelbearing was kapoet.. Changed the bearing and gone is the noise..! Funny enough is i didn't have play on the wheel.

[4x4Maniac]

If the sound is there when in 2x4 hubs locked it could be front diff, bearing inside the transfer or front prop. If the sound is there when in 2x4 hubs not locked it can only be a wheel bearing.

M2cw

[4x4 Junkie]

Thanks guys. I will work on a process of elimination starting with the cheapest first.

George I also spoke with Hoppy and if I don't get it resolved on my own, I will take it to him

$$$$$$$$$

[george]

Hi Julian.Just a quick update on my Hubs. I finally took the plunge and opened up the hub. My clicking sound come from the fact that my clutch assembly is a bit wear out. When I am in the "free" position the gear is not completely withdrawn.I would say about 95%. So basically when I drive the gear is still touching the shaft very lightly. I tried cleaning and greasing but it is still there.A bit better but still touching.For now I am just going to drive with the hubs locked till I can get a new hub.I hope this kind of make sense :alvarin: It took me a while to figure it out.

[4x4 Junkie]

Thanks for the feedback George. I hope you don't have to sell a kidney to afford those new hubs.

I will update progress as I go along

[george]

Thanks for the feedback George. I hope you don't have to sell a kidney to afford those new hubs.

I will update progress as I go along

Nah the freewheel hub is about R1500 IIRC,but I only need the clutch assembly.