Knocking When 4x4 Engaged

[Irish-Lux]

Hi all....my first post! Apologies if a similar thread has been created already, but still getting the hang of navigating here.

I bought a 1995 Hilux 4x4 about a month ago. I've had a few minor problems, but more recently the biggest one has been difficulty with the 4wd. Firstly...the shift lever for the transfer box doesnt seem to be properly connected...as I can pull it out of the box so that it doesnt work, and then fiddle with it until it goes back in. I have a workshop manual, but cant find anything explaining how it should be attached to the transfer box? Secondly...when I engage 4wd it works fine, except there is a loud knocking/grinding noise when I turn at low speeds. Not sure if it happens at all speeds, but when taking off or moving slowly and turning it can be clearly heard. At first I thought it might have been the transfer box, so i drained it and refilled with fresh oil. The old oil was not clear and honey coloured, but nearly like caramel. However it now seems that the noise isnt the transfer box, the sound seems to be coming more from the drivers side? although I cant be very sure. I'm just not sure where to even start looking...is it diff? Bearings? Joints? or maybe the manual locking hubs?

Any help or advice would be greatly appreciated!

Bernard

[moonstone mart]

Try greasing up the front prop with a proper grease gun (joints and shaft)

Mart.

[Andy]

Sorry I cant help with the stick problem, but are you selecting 4wd with the hubs locked and driving on tarmac.

[Irish-Lux]

Sorry I cant help with the stick problem, but are you selecting 4wd with the hubs locked and driving on tarmac.

Yes I had my hubs locked, but the knocking happens on soft ground and tarmac. I don't normally drive on tarmac with the hubs locked, but was testing it at home.

Does anyone have any ideas on what the knocking is? and on how the shift lever should be held into the tranfer box?

[moonstone mart]

Sorry I cant help with the stick problem, but are you selecting 4wd with the hubs locked and driving on tarmac.

Yes I had my hubs locked, but the knocking happens on soft ground and tarmac. I don't normally drive on tarmac with the hubs locked, but was testing it at home.

Does anyone have any ideas on what the knocking is? and on how the shift lever should be held into the tranfer box?

Did you grease the front prop? If the old grease is dried up inside it will knock. Done plenty at work.

I think i remember alot of hilux having probs with gearlevers but this was newer vehicle than yours.

mart.

[JasXPear]

when I engage 4wd it works fine, except there is a loud knocking/grinding noise when I turn at low speeds.

Dont use 4WD with hubs locked on tarmac for starters as there's no centre diff in the pickup.

Could be the prop or UJ but probably the CV joint on its way out.

Try it with the hubs unlocked - it probably wont click if the hubs are set to free because with this doesn't not turn the driveshaft.

Axle rebuild guide here

[Irish-Lux]

Thanks everyone. I think in the end it was just due to the tarmac....! Should have known....

thanks for all the advice!