Hey guys,

I picked up a 2-Door 1995 Suzuki Sidekick 16 Valve 5 Speed Manual.     

I started to mod it beginning with a simple 2 inch spacer lift front and rear and a NEW rear end with a locker in it.  Threw on some 31's and called it a day.  I have manual locking hubs on the front.       

On to the issue, something is grinding when in 4x4 with the front hubs locked.  It happens when I am traveling in a straight line and worsens when I turn.  The noise goes away if I get on the gas moving forward but as soon as I let off the gas its right back, it also seems to be present when I am in reverse. 

If I unlock both of the hubs and leave it in 4x4 the noise goes away, if I lock 1 hub and leave the other open the noise goes away (each side).  I have changed the hubs out and the passenger side axle/CV/half shaft but this did not make a difference.

The only thing I can thing is that the gearing in the rear diff is different than the gearing in the front diff, but why would it only be revealed when not on the gas.

Any ideas let me know I am stumped       

Check the front diff mounts, see if the drive shaft is rubbing

Wild

Is that new rear end the same gear ratio as the front?

I will check the diff mounts but what am I looking for ? Can the front drive shaft come into contact with them ?

I understand that the 2 door 5 speed has a 5.12 gear ratio and I was told that the new rear end has 5.12 gears. 

I will spin the tire and count the drive shaft rotations and post back.

Thanks for the Ideas. 

i sounds just like what i just did. the pinion mount probably broke of the differential. i just made a post to see if anybody makes an aftermarket replacement.

http://zukiworld.com/month_020103/feature_frontendupgradeswithhagen.htm

the red piece replaced where the stock mounting tabs were and most likely broke. they were supposed to bolt to the white mount.

Replying for those that may have the same issue. The rear pinion mount was sheared clean off, the drive shaft was rubbing on the bell housing.  I stupidly drove it around and now there is a hole in the bell housing.  Learn from my mistakes.

Cheers,
Brett

Fix your broken part, and use some epoxy putty
to patch the hole

Wild