Noise in front end of Kawasaki 2510 4x4 diesel Mule

[Kyle_in_Tex]

Howdy, I get to work on this next week for my boss while we are a bit slow at work. He thinks it is a 2000 or 2001 model. Says it makes loud noises when you put it in 4WD. I don't remember how many hours are on it, but the tires are down to their last 20%. Any ideas from you pros?

Last year it had troubles with the motor dying while driving along. It turned out to be something in the tank clogging up the fuel line. I blew some compressed air through the line back into the tank and so far, so good.

Compared to today's models, the thing is really kind of a turd powerwise but as long as it runs it is a decent machine.

 

[RandyT]

My two guesses would be either a wheel bearing or CV joint.

 

[ruffdog]

Check front diff for metal filings.

 

[Industrial Toys]

Continuous noise or just a loud ugly clunk? The loud ugly clunk especially coming out of 4wd is normal, I am told, even though my mule did not do this when newer. It is a dog gear disengaging.

 

[Kyle_in_Tex]

Continuous noise or just a loud ugly clunk? The loud ugly clunk especially coming out of 4wd is normal, I am told, even though my mule did not do this when newer. It is a dog gear disengaging.

Thanks for the replies, hopefully I will be able to answer your question Mon or Tues.

 

[Kyle_in_Tex]

Continuous noise or just a loud ugly clunk? The loud ugly clunk especially coming out of 4wd is normal, I am told, even though my mule did not do this when newer. It is a dog gear disengaging.

It is a loud ugly clunk. Seems to come from the rear while in 4WD. I would guess that it is a gear or tooth that is slipping. I checked the 2WD 4WD engagement, which is cable operated to a lever on the transfer case. The lever has a round spring wound tight to make it go back into 2WD when the selector is moved back. It was maybe sticking a bit from the dry dust that it was dirty with, so I put some oil on it and now it moves freely. Cable moves freely too all by itself. My current theory is that the lever did not move all the way to the home position (from being dirty) and may have caused damage from partial engagement. I am going to keep googling to find out information.
Has anyone had to replace the carrier bearing on the driveshaft that goes from the back to the front? It is looking kind of dry too, but I can't detect any looseness while trying to shake the shaft. It has a grease zert but I doubt it has been lubed in a while.