2001 Sportage 4WD front end clunk chatter noise

[bnentrup]

I am having a bit of fun trying to figure out my 2001 kia sportage 4WD. I have metallic sound in the front end, both wheel sides. The sound started out as a minimal grinding, similar to when your brakes need replaced. However, I have checked those-- to find that this is not the issue (I am for sure about this). the noise often starts with the light grinding sound, and then ends in a 'clunk' and it somewhat dissapears for a minute.

It mostly occurs when the car is taking of or especially when the car is slowing down. It will do it even when the brakes are not applied.

I had the notion to engage 4WD Low and it seemed to take care of it. However, a few days of drive in 4WD low, and it had another 'clunk' sound.

The best reason I can come up with is that the 4WD is not fully disengaged when it is in 2WD mode, and the 4WD is not fully egnaged when in 4WD.

Anyone else had this problem? I doubt there is an actuator since it is a manual 4WD (The sportage is automatic transmission though just to clarify).

Thanks for your help!

[mgbgt1972]

Well if you drove for 'a few days' in 4WD low you are damn lucky your transfer case didn't grenade it's self!

Seriously were you driving around for a few days in 4WD low?

You should only drive in 4WD mode low or high on surfaces that require extra traction, snad, snow, muds etc! Basically if you can scuff the surface you are driving on with the toe of your boot !

The grinding noise you h ad 'before' you drove it for a few days in low was probally the hubs, the vaccuum have a history of failing, (vaccuum lines) and letting water and dirt inside the assembly and contaminate the front bearings. The grinding followed by the clunk could just be the hubs trying to engage, take em off, clean them repack them with greese and check for leaks in the vaccuum lines.

[bnentrup]

I mean 4WD High-- I was a bit backwards when I made the comment, but I read the manual before I did anything...and indeed, 4WD H --- Which in my eyes indicates 4WD part time even I though I realize that KIA has the auto-hubs.

And the more I read, the more I see that your reply is right on track.

History: when I bought the kia, I was told by my 'friend mechanic' that the vacuum lines for the abs (which obviously these are for the 4WD) were shot. He replaced them before we left the car lot with a smaller tube. The line size may be fine, but the fact that they were bad at one time indicates stress to that area.

I bought the KIA with the dealership stating that the 4WD and brakes needed work. The brakes have a warped rotor (pretty smooth rotors, but they shimmy when brakes applied). Could this also indicate a premature bearing failure which also ties back to the 4WD hubs?.

I did not know that the Hubs existed until yesterday when I began to research sportage issues. I will indeed clean, repack the hubs, and likely replace the vacuum lines with a bit larger tubing.

Thanks so much,

[mgbgt1972]

You could pick youreself up a pair of WARN manual locking hubs, benifits are they are a few hundred dollers cheaper than the OEM replacements, they are much more durable and they get rid of all the vaccuum stuff, they take 15 min's a side to change out and cost around $120 to $160 depending where you get them from.

Downside, you have to get out and lock the hubs before yo can use the 4WD modes.