Found the clunk and had an epiphany. Dana 60

[SquareRoot]

Had a slight clunking issue with the front diff. Only noticeable under 5 mph when turning. Pulled the hub today and discovered the inner spindle nut was about 3/4 turn from being snug. Both sides. Blame it in the young soldier who serviced it many years ago. FYI, I pulled the axles from a CUCV.
Anyway, it got me thinking because I pulled everything apart just to see how it works. First thought was, "my God, those axle shafts are gynormous"! They must be an inch and a half in diameter. I noticed the u-joints between the inner & outer shaft have no zerk fitting? The joint feels tight with zero play.
This got me thinking and I'm looking for confirmation on this: If you have a part time T-case and lockout hubs then the shaft (and u-joint) ONLY turn when in 4wd, correct? If so, I would assume there are a lot of trucks out there where the front diff has virtually no miles on it compared to the rear. If you never drive in 4wd, the only wear on the front axle (not counting suspension and steering) are the wheel bearings.
What say y'all?

 

[nvrenuf]

Yeah, they typically have very minimal where compared to rear or full time front axles.

The front end parts can move while driving because the fluid current in the tcase will slowly turn the front driveshaft. There’s no real speed or power going to the front axle so no real appreciable amount of wear.

 

[SquareRoot]

Still amazed at the size of the Dana 60 components.

 

[AuroraGirl]

Had a slight clunking issue with the front diff. Only noticeable under 5 mph when turning. Pulled the hub today and discovered the inner spindle nut was about 3/4 turn from being snug. Both sides. Blame it in the young soldier who serviced it many years ago. FYI, I pulled the axles from a CUCV.
Anyway, it got me thinking because I pulled everything apart just to see how it works. First thought was, "my God, those axle shafts are gynormous"! They must be an inch and a half in diameter. I noticed the u-joints between the inner & outer shaft have no zerk fitting? The joint feels tight with zero play.
This got me thinking and I'm looking for confirmation on this: If you have a part time T-case and lockout hubs then the shaft (and u-joint) ONLY turn when in 4wd, correct? If so, I would assume there are a lot of trucks out there where the front diff has virtually no miles on it compared to the rear. If you never drive in 4wd, the only wear on the front axle (not counting suspension and steering) are the wheel bearings.
What say y'all?

I think I remember there being something about the low hanging pinion vs the high pinion and the direction of the gears , so 4wd moving forward is like wear as moving rearwards is to your rear diff. But Im not up on that science, I just rmemeber seeing it brought up where someone wanted a ford high pinion 44 because of that

 

[Radiohead]

Still amazed at the size of the Dana 60 components.

Dana 60 'taint effin around...

 

[nvrenuf]

Still amazed at the size of the Dana 60 components.

It’s always been the beef of the inner / outer knuckles for me, they make a 1/2-3/4 ton housing look like toys.