I have a 1992 Jeep Cherokee Lerado I6 4x4. It has the dana M 30 front axle and the Chrysler 8.25 rear axle, AW4 transmission, 242 transfer case.
New:
Entire braking system except Master Cylinder, Booster, and Proportion Valve.
All tie rod ends.
Right side hub.
Front UJoints.

As I am driving (only between 5-25 mph) I hear a Click sound from the front end. Aprox 3 clicks per second. Any ideas?

 

think im in the same boat. i just replaced my pass side u-joint and i get a clicking sound. no front doors so its easier to hear for me. does it sound like something binding up then popping?

 

That sounds like one of the needles moved on you. Hmm maybe thats what my problem is...

 

In my case its hard to hear..... LOUD exhaust lol

 

BTW..you dont have a dana 35 front.

Its a dana 30.

 

yea i know...... typo..... ill fix... XD

 

I think I am having the same problem as you are describing. When it cools off outside (104* with the heat index) later I'm going to go out and try to find the problem. Mine is not constant though, mostly when I am slowing down, so I think I may have a cracked rotor or something is binding when I brake

 

Well I believe i have figured out the clicking noise..... I replaced the rotors not to long ago. Well the holes in the rotors for the studs to go through are too big. Yes i had it torqued to 95 Ft Lbs. As I am driving they rotate back and forth.... I replaced them with the best ones from autozone. Still doing the same thing. I put 4 new lugs on the front.... all they had until tomorrow. I also discovered there is another lick/pop noise that ironically hits the same beat as the rotors moving. My Ujoints on the front shaft need replaced.

 

Jack up the front end, grab the tires and spin. If that doesn't reproduce the sound try spinning the front DS.

 

It does make the same noise... on both sides.

 

Ok time for a quick update.... Just finished replacing the ujoints on the rear shaft and the front shaft...... still the same noise. Drove it before reinstalling front shaft... Same noise.... Friend of mine told me to remove the front axles and drive it to see if it goes away... That will have to be a different day. Also when i put it in gear after backing up it clanks..... Any ideas???? I hope not trans......

 

You need to keep the stub in there on the knuckle side or your wheel will probably pop off. Did you replace the u joints in the axle shafts?

 

......Huh? yes both wheel joint ujoints are new....
How would the wheel fall off? The hub assembly would still be in place....

 

Hole ID in the rotor is always larger than the stud OD, that's how they "float". Also why you never want to over torque a wheel, it will warp the rotor. With the wheel off can you thread the lug nut on all the way to the rotor? Does the assembly tighten up?

 

Off the truck it did tighten down. Haven't done it on the truck. Ill try. I know the hole id is going to be bigger than the stud od but when its more than 1/8 of an inch seems a bit to much.

If I have time tomorrow, I am going to take out the front axle shafts and put it all back together. If the click is gone then I know its either A Ujoints (even though they are new) or B front diff.