Bad Power Lock??

Back to square one.

Original issue. Weird rattling sound when releasing gas and cruising down from 45+ mph to about 20.

Clutch and throwout bearing is good

Transmission Rebuilt
Rear axle new bearings (wheel and differntial)
Transfercase was swapped out with a known good unit.

After diagnosing everything it looked to be the rear end, so i went through it. It was a little loose and it did sound like gear rattle. New bearings and it was tightened up with proper backlash and pre-load.

I took the jeep for a ride and the noise was still there and a bit more horrible sounding.

So now i need to go back into the Rear. Only thing i did not look at was the power lock. I did not go through it, just did a physical inspection and cleaned everything and through it back in. Now I am suspecting the Power lock having something wrong. It seems to work just fine, when off road at slow speed it moves both wheels fine and has no bad sounds. Once i get on the road the Jeep sounds like it wants to blow up. So what is inside the power lock?

 

Re: Diagnosing bad Power Lock?

Does anyone have a diagram of the powerlock? I cant seem to find a drawing for one online

 

Re: Diagnosing bad Power Lock?

Probably nor exactly what you're looking for but...

http://www.tantel.ca/Images/The Sludge Pile/Section_M_Front Axle/Power-Lok/

H.

 

Re: Diagnosing bad Power Lock?

When i had it apart it looked clean. Nothing was broken. I replaced all bearings inside the axle and reset the backlash. I did have a loose pinion before, you can see the yoke move froward and back about 1/4 inch. The bearings were all swapped out. I am not sure what was done before i got the axle. When i got the jeep i pulled the axle out of the ground because the jeep was apart. Maybe it could be gear noise, i dont know, i didnt have any broken and odd looking wear on the gears. I am wondering if something is loose in the powerlock or broken in there. i did not notice any noises when i had the diff on my bench but i did not shake it. Everything happens above 35 mph.

 

Re: Diagnosing bad Power Lock?

I pulled the power lock today. What i didnt like is i had some metal glisten in the oil when i drained it. Hoping it may just have been for breakin. The carrier bearings looked great.

I pulled the case apart.

Here are pictures of the clutches i pulled out. I thought the wear patterns were very odd.

right side (Both Sides)

 

Re: Diagnosing bad Power Lock?

Left Side (both Sides)

 

Re: Diagnosing bad Power Lock?

What i did find which i am not sure if it should be like this was the middle cross shaft. The center pin seems to be bent.





Looking at the clutches should i replace them? There wasnt any rust inside the carrier it was in good shape.

 

It was the camera. Nothing is blue or have evidence of overheating. The discs are either black or shiny. There are a few with oval patterns that i am concerned about. The center pin holding the cross together is worrying to me also. I am not sure if there is a spring to hold it closed and allow the side to spread, because right now there is no spring action, it is open and flops around.

 

I will shoot some pics tomorrow. they looked fine to me, but i didnt clean them yet.

 

Is the "black" portions the clutch material? I am guessing the clutches i have are the early steel ones, since there looks to be two different kinds. Did the steel ones have clutch material on them or did they just right metal to metal?

After pulling everything apart i am still concerned about that rattling down sound i have when coming down from cruising speed. I do not see anything really out of play. When i pulled the halves apart i noticed that there is tension there when unscrewing the bolts, so it wasnt loose. I am trying to think about what would cause the noise i was experiencing.