1996 k1500 banging in the front end

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Joined
Nov 27, 2018
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Location
phoenix AZ
Just became a member and thanks to all for help with repairs in the past. I am compelled to write this because of all of the dead end posts where no final answer was given. I have a 1996 GMC Sierra k1500 with a 5.7L motor with 226,000 miles. My problem started when I was on an on ramp to the freeway. Out of nowhere this violent metal to metal banging started happening seemingly from the front drivers wheel. I pulled over and did a visual inspection and found nothing. So I limped it along the shoulder of the freeway at 5 mph with a constant bang......bang.......bang, then after about 3/4 mile it just went away! Drove it for a couple of days then it happened again backing into a parking spot. I have a shop with a lift and I brought it there and inspected wheel bearings, all okay. i had a half shaft that was installed new 6 months ago, but i bought and installed a new one to eliminate that. still bang.....bang. So, then I removed the differential carrier and took it to a reputable axle specialist and he tore into it and found nothing out of the ordinary but one little needle bearing but did not believe that matched the symptom. He had me call a transfer case pro and I described the problem and he said he has not run across a symptom like mine and said he needed to drive it. So, with high hopes the new bearing was gonna fix it I re-installed the differential carrier and drove it a couple of days and it seemed fine until bang.....bang....bang. I had noticed this whole time that the light illuminating 2HI was intermittently going on and off so on a whim I went to the dealer and bought a new switch to eliminate that as a problem......and never again heard bang....bang....bang. it was the switch trying to engage the 4wd. Soon I will have the transfer case gone through to the tune of $1500 im sure. I just wanted to share my symptoms......and the fix in hopes of helping someone else out there. Cheers!
 
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