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Can someone help me. I got this really loud 'stress like cracking/grinding' noise coming from the front wheel. I installed the new shocks(4) and the ABS light has been on and off at times. Ever since then that annoying noise has been there so I replaced the calipers, caliper bracket, brake pads and hardware and still sounds like this. 4WD 'on' or 'off', the noise is there. Driving forward and reverse it's there. It's very random too but only happens when I step on the brakes. I can feel it in the steering. The video link is below so please view it and give me some ideas of what you guys think it might be. Thank you

cars :: NewProject3.mp4 video by cash555 - Photobucket
 

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I don't know what it is exactly but is sounds like it might be a bad hub bearing. Also you might want to get it checked before you catch something on fire if you watch that video closely you can see it shooting out sparks.

You mentioned that your ABS light is coming on and off? Have you checked your ABS wheel speed sensor and made sure that its not rubbing on anything? I would start there take the wheel off and start ripping everything apart til you find it. It shouldn't be to hard to find if its throwing sparks out because you should be able to see where its grinding at.
 

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Discussion Starter #3
Front bearing are new and only has about 2500 miles on. ABS sensor is fine. Just replaced the rotors today. While it was still off the ground I spun the front wheels and it seemed to be fine. Drove it around and that noise came back. Could it be that the brake line has air in it? Can I just take out the ABS fuse and disable that option for now? This weekend I will take apart the hubs and check those out.
 

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It's something serious there are sparks flying out when it makes that sound in the video. If you can't figure it out then you need to take it to a shop that can before you cause serious damage or a fire from the parts getting to hot.
 

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Discussion Starter #9
Right after I put the new shocks in the ABS light came on and that was my hint. Then after 10 miles or so of driving, the scary noise came about. After much worry I decided to replace everything dealing with the brakes up front but the piece of poo noise is still there. The hubs are new according to the service record and receipt.
 

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Discussion Starter #10
I tested it out tonight and I didn't see any sparks. Drive around with lights off and buddies on both sides of the road...and no sparks.
 

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Right after I put the new shocks in the ABS light came on and that was my hint. Then after 10 miles or so of driving, the scary noise came about. After much worry I decided to replace everything dealing with the brakes up front but the piece of poo noise is still there. The hubs are new according to the service record and receipt.
Man I'm not sure what to tell you......maybe try to change the hub again, just to see

watch your video then I beg to differ with what your buddies saw.
I saw them too.....almost like the rotor is hitting the caliper in some way
 

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When diagnosing symptoms like this, you only need to look at the things that are moving when the truck is moving.. Take the tire off and inspect the rim for damage. Take the caliper off and inspect the inner oring that seals the piston from brake fluid leaking out. Look at the brake pads to see if the pads are cracked, cracked pads will make a crunching noise. Now look inside of your hub to see if your bearings are alright and if they were installed right with an adequate amount of grease. Inspect your ujoint to see if it has any play what so ever. Inspect your seals and then finally see if anything is inside of your axle causing that noise. While in there, also notice any trash or if anything looks wornout and possibly compromised.
 

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Discussion Starter #14
Bad wheel bearing and locking hub. The snap ring inside wasn't snapped in because it must have been stretch out by the previous installer. ABS sensor melted away into the wheel bearing. It's all good now.
 
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