Clicking and popping noise not cv shaft - Busted diff?

[secrethq]

Hey guys,

So I just did the front cv shafts and passenger wheel bearing in my 2002 audi s4.

Everything ran like a dream, sounded great for 2 days then I started getting bad clicking/popping noises under load. If the car doesnt pop in makes a horrible vibration throughout the whole drive train shaking the car like something is binding up.

Pissed that I bought autozone duralast cv shafts I got a replacement shaft thinking that I bought a defective shaft straight out of the box. Well I changed the cv axle out tonight and the car is still popping and clicking.

There did seem to be some play in and out and forward and backward on the diff flange.. but im not sure if thats excessive.

Could really use some brainstorming.. Do I have a broken diff? Is there something in that flange that I need to change?

I have a video spinning the tire on jackstands and the clicking... i'll try to get it uploaded here soon. It sounds like its coming from the passenger side.. but its kind of hard to tell.

If anyone can point me in the right direction I'd really appreciate it.

Makes the noise/symptom in forward or reverse, straight line or turning... gyrations and noise however seems to work themselves out around 40mph.

Thank you very much for your time!

[secrethq]

Nothing? No ideas?

[Bordom]

Where's the video you speak of?

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[secrethq]

Not sure how to post the vid from my phone... but ill try a share link and embed.



I was changing tranny and diff oil in the vid but it still makes the same sound full and capped.. just happened to video then.

[secrethq]

Ill try to get an in car driving vid up tonight... sounds a bit different.

Thanks for the help in advance!

[Bordom]

Wow... front diff? Definitely sounds like you broke something in there

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[secrethq]

is there something to change in that flange? or whats the fix?

I've got a parts car but id rather not swap a diff n tranny if I can just rebuild something in car?

I did a wheel bearing at the same time.. the only other thing I can think of is maybe something with the caliper or hub?

Just grabbin rope at this point.. would rather not send it to audi for a $126/hr inspection... I'd still do the work myself anyway.

[Bordom]

If you sent it to Audi, they would just tell you to buy a new tranny. Guaranteed.

At this point, pull the tranny and see what's going on in there. Probably destroyed your diff somehow or the pinion gear is broken.

If you have a small boroscope, try feeding that in there so you can see what's going on without doing all the work

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[vavJETTAw36]

If you sent it to Audi, they would just tell you to buy a new tranny. Guaranteed.

At this point, pull the tranny and see what's going on in there. Probably destroyed your diff somehow or the pinion gear is broken.

If you have a small boroscope, try feeding that in there so you can see what's going on without doing all the work

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If the boroscope does not lead to anything, a mechanics stethoscope will help you pinpoint exactly where the sound is coming from... But unfortunately it sounds like the differential especially if you changed the stub axle after the sound. I wonder what could have happened between day 1 of changes vs now??

[secrethq]

Not sure what happened.. in the 4 years ive owned it ive literally never launched the car. Its my daily driver.. and i drive it like grandma.

There was no beating on the car inbetween sounding great to this

[james 408]

can't tell in the video, but you're sure it's on the diff side not the wheel bearing side?

I've broken many diffs, but never had a mild clicking be the result (major clicking and almost won't even roll). not sure though.

[secrethq]

Just in case someone stumbles on this problem. This turned out to be the rear cv flange on the center driveshaft. Took a replacement off my parts car, repacked with grease... drives perfect no noise no vibrations. Cheers.

[RocksForsSale]

Glad you fixed it! Sounded like the center diff from the video.


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