Front popping noise when in 4wd

Hey folks —I’m stumped and need some help.

recently on an overland trip my 2005 taco developed a popping noise in the front end. The popping would occur when moving and turning, when shifting from drive to reverse (and vice versa) whether moving or at a stand still.

What is weird is that is only seems to be when I am in 4wd (I can’t seem to replicate the sound when I’m in 2nd).

some pertinent details:
Ome struts
Rocky road outfitter UCA’s
Energy poly bushings in LCA
Relatively new cv axles and ball joints
ECGS needle bearing swap done

Any suggestions are appreciated. It’s the 4wd part that I can’t figure out.

 

Are you on pavement during the noise? What are the road conditions? 4wd tends to make some funny sounds even if all is normal.

 

Get somebody to drive it and make the noise and pinpoint the location maybe put all tires In the air or mounting a camera in certain places If it’s only in 4WD then I’d listen around the transfer case the front diff and your new cvs. Might want to make sure your front diff has oil in it and no chunks of metal come out.

 

Only in 4x4. Well Front Drive shaft ujoints possible here

 

Did you ever figure out what the issue was? I’m having the same exact problem and can’t figure it out.

 

Not enough info to say for sure. But if you hear a popping noise when in 4X4, especially when accelerating it could be a stretched drive chain inside the transfer case. If the truck has been used in 4X4 when on a surface with good traction it puts the chain under stress. It stretches and will slip on the cogs and make a popping noise. It does it most often when you accelerate from a stop. Once up to speed it will go away.

This is inside the transfer case.



A lot of folks think, and even post here and on other sites, that it is OK to drive in 4X4 on pavement. They think that just because their truck didn't blow up at the moment they aren't doing any damage. It just takes time for it to show up.