'96 XJ AW4 here and for a while I've had this clunking sound just when I come to a stop and right when taking off again. From the feeling and sound if it I'm guessing it's coming from somewhere in the drive line somewhat toward the rear. The sound doesn't repeat itself, it's just one solid clunk when stopping and again when starting. Asked around about it before but nobody had any solid ideas about it.

So couple days ago I see this write-up describing how to grease the slip joints of XJs 97 and up. And in it is a description of a sounds exactly like what I've got. So all happy I've prob found the culprit I re-read the write up again and see it's only for, yes 97s and up.

http://www.jeepforum.com/forum/f11/g...ite-up-357569/

What's the deal with trying to do the same to my '96? Is my drive line that much different from the 97?

 

It is a very easy job. Can be done in 30 minutes. If the transfer case is a 231 on the 97, the job will be nearly identical. No writeup is really necessary, its quite a basic job. Watch a few of them, read up a few of them until you get the "jist" of it. You might consider doing the rear shaft u-joints at the same time since you are going through the trouble.

I used a heavy-duty zip tie to secure the rear portion of the boot to the shaft. It has been just fine for 2+ years. You can probably get the proper retainer (boot clamp) at any auto parts store.

 

x2. The driveshaft looks and functions the same regardless of year. Splines, u-joints, etc. may be different but the function and maintenence in this regard is the same. If the problem persists then you most likely have a worn u-joint. Let us know how it goes

 

You sure its not a brake caliper?

 

Sounds like the slip yoke to me. But, I think the difference from 96 to 97 is the transfer case. Yes, it's still most likely a 231, but the shaft housings are different. I'm pretty sure you still remove the shaft the same way, but with how the transfer case is setup on the 96 (and older), you may loose some tcase fluid in the process.

New style...



Old style...



See the differences in the housings?

This is just what I've come across. To be honest, I've never had an XJ that was 96 or older. PLUS! 96 was the bastard child of the XJ's. It was a transition year, so it had a little bit of old and new on it.

 

I have a 96, and it has the newer style 231 (like the top picture).

 

Actually, now that I think about it... the OP must have the new style. IIRC, since the tcase fluid goes out into the housing on the old style, it's already lubing the splines. So I'm thinking the OP has the new style 231 (like the first pic) because that style isn't lubing the splines with tcase fluid.

 

I'm not with my jeep, or at the store. Does anyone know the diameter of the clamp? Thanks...

 

I am going to chime in on this with a different idea. Yes, lube that slip joint. However put the tranny in neutral and rotate the drive line. If you get a lot of rotation then what you are experiencing is a worn ring and pinion. It is common, not life threatening, just annoying