Noisey front hub

Hi, I thought I had asked for help on this but may have posted in the wrong section? :blush:

2003 Jimny petrol 1300 cc

OK the problem is as follows:

My friend had never used the 4wd system and I advised that he should once in awhile. He took it onto the beach and engaged the 4wd and used the car for a short while. When he disengaged the 4wd and drove onto the open road there was a sound that sounded like grating metal, it was a rythmatic sound and varied with speed. If 4wd was engaged at any time tarmac or loose the noise went away, within a few seconds of selecting 2wd the noise would return. It appeared as if one of the freewheel vacuum hubs was not disengaging fully? After swapping the hubs and trying ect I think I have narrowed it down to one hub. I replaced all the vacuum hoses and cleaned the filters ect and the noise is still there! I decided to engage the hubs manually and refit them and remove and plug the vacuum lines, he is now running around with the front hubs driving the front diff/prop, this was a 'keep him on the road' idea untill he could get a new hub which I THINK is the problem however, now after a few weeks running around he says he has a new sound, it seems to be coming from the front and he said it only happens when climbing hills and when the engine/transmission is under load. The transmission lever is not in 4wd and I have not heard the noise yet I will have a listen later in the week, this car is driving us around the twist, any ideas guys and girls?

Many thanks in advance

It appears that you've identified the problem, i had a sticking hub and it had the same problems that you describe. The fine holes get clogged up with grease. I don't know what the problem is with the new noise though, the only thing i can think it could be is the diff being low on oil and its worse when on hills.

You should have disengaged them rather than engaged them really for using on the road, mine would engage fine but i had to take them off to disengage them after using 4wd. Best solution by far is to bin them and fit manual hubs.

Hi and thanks for the reply.

The problem was my friend wanted to be able to get 4wd if need be, by locking the hubs manually and refitting he could engage 4wd and the hubs would already be engaged, disconnecting the vacuum lines stopped the vac trying to unlock them. The new noise was a little worrying as I thought that perhaps that damage was being caused by the hubs being locked although I cannot see how? The only downside having the hubs locked (without 4wd) I can see is the slightly increase drag/wear on the rotating differential/prop ect. So I am unsure of my next move without it costing a fortune stripping everything in site.