Clicking noise from right front wheel when turning in 4wd

[Tas GQ]

Hi guys, i have an issue with a horrible clicking noise that comes from my drivers side front wheel when i turn while it is in 4wd. It is a gq patrol, i only just bought it this week and the guy i got it off said it was hard to turn the hub to the locked position on that side, you needed a pair of pliers to get it all the way. First time i put it in 4wd and turned i heard the noise coming from the same side that was hard to turn so i pulled the hub apart to have a look. I started cleaning the hub assembly and noticed that the snap ring that holds the clutch spring into the driven clutch wasn't in place, it was just lose below the clutch spring so i cleaned all the old grease off everything and put a moderate amount of grease over everything and got it working nicely. Put it back on and the the noise was still there. Does anyone have suggestions as to what this may be? It only happens in 4wd and while turning. It's a 90 model with manual hubs. Also when putting the hub assembly back on does it need to go a certain way? I put it back the way i removed it but i'm unsure it was right to begin with. The driven clutch has a tooth missing (not machined in the first place) does that need to line up with anything? I didn't pull the snap ring off in front of the drive clutch, i only really removed the hub assembly. Thanks in advance Richard.

[Robo]

Sound like a CV joint, CV should only turn in 4X4 mode.
my money's on a bad CV.
tooth missing dosen't sound good.

[Tas GQ]

The gap where the missing tooth is looks like it was made that way not broken
is there a way to test if it's the cv joint?

[Robo]

how loud is the click sound.
with windows up louder than mild stereo.
I'm no cv expert, will make a loud sound.
louder than you clapping your hand as hard as you can.
Remove to check you don't want to damage anything else.
it could be smashed, or has tight spots "worn out"
they are cheap on ebay.
personally not sure that's such a good idea for a part that works so hard.
good chance they are made of inferior materials.
get yourself a repair manual world of info, and subject is surely covered try the site search engine.
How to replace a CV joint.
or simply pay someone to fix.

[Tas GQ]

It's a fairly loud click mate, you could hear it with the windows up and a little bit of music. I have a Gregorys manual and have done numerous searches relating to it, there is a really good write up by YNOT i have found. I was wondering if it was the CV, i haven't had much to do with 4x4's but i'm pretty confident with pulling stuff apart and fixing it. I think i will get a seal kit and pull it apart, i got a few parts with it, one of which was a cv so if it is nackered i will replace it.
Thanks for the advice Robo

[Col.T]

G'day Tassie,
Bit late but,,,,How certain are you that it is the R/H hub? Have you had someone listen outside while you crawl slowly in 4WD on hard lock? These noises can be a bit misleading sometimes.
If it definitely IS the R/H hub, and the near side one is perfect, maybe pull them both apart and check for assembly order and condition. I've not had a missing spline on either of my two models, so that could be a concern.
You'd be near downloading the full workshop manuals and I know there is a full diagram for the hubs etc. included.
If the noise is back in the drive train, Robbo is looking the man
Regards,
Col