Rear axle noises==BJ8

[Jerry]

I have two noises that show up in the rear axle.
1. A noticeable clunk when you let the clutch out indicating that the crown and pinion are not matched up well. You can turn the prop shaft 3/4 inch prior to engaging the gears. The axle is the only part I did not go through on the car since it came wrapped in plastic with brand new paint. I thought it had been finished. The person we bought the car from had taken the car all apart and was just getting ready to put it back together when he died of cancer. So, axle has to come out for this.
Question: Could the clunk come from anything else in the axle area?
I also noticed that the axle at full compression is showing a rub mark on the underside of the rear tunnel from the hardy spicer joint rubbing.
I have new rubber stop bumpers, so has anyone put spacers under these to limit the compression height?

2. Second noise only happens at hard right turns and appears to come from right rear wheel. A metal clicking sound. Any guess as to what this could be? So far, I have only thought of the 72 spoke wheels slipping on the hub, but I can see no evidence of this? I am not sure what evidence would be there, but I assumed the ridges of the hub would be bent.
Any ideas?

thanks for your help. PS: u joints were all replaced with the restoration as was the outside axle bearings (by brake drums).

Jerry
BJ8 67

 

[Keoke]

1. A
Hi Jerry You do not have to pull the axel assembly out . Pull the axles, drop the drive shaft and remove the pumpkin. I think you have to set the pinion to ring gear clearance.
If ther s a pro shop close that does this use em it is a PITB to do.--Keoke

 

[Jerry]

Thanks Keoke, I was wondering if that pumpkin would come out without removing the axle. The repair manual is a little vague on that. I set the pinion and ring gear on my TR3A, and I agree it takes a lot of think in 3 dimensions to figure out how to shim it up, but I figured it out eventually. I may take a look at the gears to see if they are damaged first.
The clicking noise is bothering me most. I don't have a clue what it is.
Jerry

 

[HealeyRick]

Also check your wire wheel to spline fit. Wear here can cause a "clunk" when the clutch is engaged.

 

[tahoe healey]

May also be the knock-off's are not as tight as they need to be. Also check the shocks/dampers for tightness against the frame. Often the mounting holes become elongated and the unit can move a small bit.

 

[bob hughes]

Part two - metallic clicking sound - check the spokes if they are loose or broken you can get that sound,
come to thing of it when that happens they click all the time, but worth a check anyway




Bob

 

[Jerry]

Here is what I have found so far. The drive shaft grease nipple is rubbing at times on the top of the tunnel.
The Hardy Spicer edge rubs at times on the passenger side of the tunnel (right side). I found oil on the drivers brake shoes, but not much. The hub nut on the passenger side was loose.
So, waiting for some parts to fix everything. I shall have to see if the axle will shift to the left side 1/8 inch.
Jerry

 

[Healey Nut]

Bad U joints ?