Navajo 2WD V6-4.0L OHV (1992)
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This type of noise will occur on 4WD vehicles with very low mileage.
Repair
1.
1991 Navajo - Verify that the lubricant has been replaced with ZZL0 26 001 (part number of lubricant).
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If the lubricant can not be verified, extract the existing lubricant from the differential with a suction gun.
NOTE:
Breaking the carrier seal is not a recommended method for extracting lubricant.
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Refill the front axle with 56 ounces of lubricant (ZZL0 26 001).
2.
Front Axle Break-In - As the vehicle accumulates 100 - 200 miles (with hub engaged), differential motoring torque reduces significantly. Front
axle break-in instructions are listed below.
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Engage 4WD
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Shift out of 4WD without disengaging the hubs.
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Drive the vehicle with the hubs engaged until 100 - 200 miles are accumulated.
NOTE:
If the vehicle is operated in reverse (backed up) the hubs will disengage and require engagement again.
After Break-In and/or Lubrication (ZZL0 26 001) Change
If the "ratcheting or "buzzing" noise is still heard in 2WD (shortly after 4WD disengagement) replace the hub that is not ratcheting.
NOTE:
Replace both hubs if the vehicle is a 1991 Navajo built after 2/91 1992-93 Navajo or 1994 B-Series built before 9/20/93. Refer to the yellow stamp
on the upper radiator support for the applicable build date.
RATCHETING NOISE IN 2WD
This noise occurs during turns or when the suspension travels through its normal range of motion (stroke). The noise is more noticeable in cold weather
with new front axles.
Repair
Refer to the instructions listed under "Buzzing Noise In 2WD After 4WD Engagement."
BUZZING NOISE WHEN ENGAGING 4WD (Electric Shift)
This noise occurs from delayed 4WD engagement or no engagement. This may be caused by damaged auto-locking hubs. Modifications to the
auto-locking hubs and transfer case assemblies since March 31, 1991 prevent hub damage and provide unrestricted engagement.
Repair
Refer to Service Bulletin R, 002/93 for transfer case modification procedure.
POPPING NOISE FROM FRONT AXLE IN 4WD
Confirm that the noise is coming from the hubs by steering the vehicle in a tight turn on dry pavement. Repair.
Replace the hub assembly that is creating the noise.
NOTE:
Replace both hubs if the vehicle is a 1991 Navajo built after 2/91, 1992-93 Navajo or 1994 B-Series built before 9/20/93.
Refer to the yellow stamp on the upper radiator support for the applicable build date.