Hi Guys,

When the throttle is fully closed, and I am descending a hill (in low or high), going exactly 2mph, I get a noise that sounds like it's coming from low on the front-end. It sounds like trying to put a manual car into gear, and not quite getting it all the way in. It does it constantly in 2wd, I'm not sure if it does it in 4wd. If I am going faster than 2mph, it won't do it; it only does it at exactly 2mph. I thought maybe it was the chattering noise I've seen you guys writing about, but it sounds a little different than what you described. I will try to adjust the shift linkage tomorrow anyway, just to rule that out. Any ideas?

Thanks,
-Matt

 

not sure but it sounds like the actuator may not be working right for the 4x4 in the front. It could be not disengaugeing or ingauging all the way! Just a thought

 

Is there a way I can disconnect the 4x4 actuator to see if that is where the noise is coming from? It seems to go in and out of 4wd no problem, but the noise really does sound like something's attempting to engage.

Thanks,
-Matt

 

Really sounds like you need to adjust the shift linkage. Try it and see if the sound goes away. The griding sound is exactly what a misadjusted shifter does. It usually only happens in low range.

Putting it in 2x4 might rule out the 4x4 actuator, especially since you said it seems to function properly.

The gear slack makes a little noise, I wonder if you are hearing that. It would have to be relatively bumpy to do this.

How is your diff locker, is it working ok? Any sticks stuck in the front somehwere?

I think someone somewhere had their KEBC make this sound when there was something wrong with either the motor or the gears.

 

I adjusted the shift linkage this morning, and the noise is still there. Let met try to describe the problem better: I am going down a slight hill, on pavement, in 2wd with the shifter in High. Once it slows down to exactly 2mph, there is a loud clicking/rattling noise.

After reading some of the other posts, I tried it out after removing the fuse under the seat marked "Eng Brking". The noise went away. After this, I figured it was probably the KEBC actuator. So, I put the fuse back in, and tried it again. The noise does seem to be coming from the actuator. I've heard others say they can hear some noise from that area, so I'm curious what sorts of noises others hear?

Also, since we still have about 2 feet of snow on the ground, I haven't been able to go down any really steep hills with good traction (that is, I don't really know if the KEBC is working well or not, since I basically slide all the way down the trails in the snow).

On the road, however, the KEBC seems to work ok (and seems to be in effect from 5 mph, on down till 2 mph, when the noises start). It does make the whining noises after I turn the key off.

I appreciate any help you guys can give; you've all been real helpful so far!

2wd to 4wd and back works ok, the front diff lock seems fine (although I don't notice a huge difference when using it), and everything underneath is nice and tight. I have gone on several 10-20 mile trail rides in the snow, in low and high, and everything works great. It's when I head home, and I come down my street to my house, that I start to hear the noise.

BTW, it's only about 3 weeks old, so it's still under warranty.

Thanks,
-Matt

 

Your engine braking servo cycles in and out at exactly 2mph. When going down a hill at 2mph the servo will cycle in and out constantly as the vehicle speed goes up and down slightly. It will whine and chatter a bit as it goes through these cycles. I think you'll find that the noise is normal.[img]i/expressions/face-icon-small-smile.gif[/img]

 

It's the bearing in your clutch. been there.

 

This has been discussed before if it is the same thing. The brake servo releases to prevent stalling the engine, then you roll slightly faster and it kicks in again slowing you down slightly, then it cycles again, and again. This happens when the incline and speed are within a certain range. If it is steep enough to sustain constant speed you are ok. If it picks up too much speed, it will kick out and down you go. Sometimes you are carefully crawling down a ledge and let you speed bump up a bit and the brake kicks in and you can go over the front, especially in 4wd. I have though about wiring in a brake by-pass switch for these cases. I think the E-brake idea is a little better on paper than it works on the trail.