Metal-on-metal noise on inside wheel when turning

[mwmoes]

I have a 1993 Bravada with 195000. Love the car and enjoy working on it. Fortunately my wife doesn't mind taking the T to work (we live in Boston and only have 1 vehicle) ...

Anyway, the first initial problem was with this metal-on-metal noise in the front end I referred to in the subject line. It would only occur when turning at an intersection. Changing lanes does not cause the noise. The noise has a constant pitch, similar to what you get from fingernails on chalkboard. I could still execute a full hard turn such as when parallel parking. Then over the span of a few days, things got progressively worse until I could barely make a turn at an intersection by making it as wide as possible as the front wheels would nearly lock up when turning, but yet I could still drive straight.

For my first repair, I pulled the wheels off and found both ball joints on the left side were rusted and seized. I replaced those and also those on the right side (note that both upper ball joints had rivets so were original). I also found one of the shocks in bad shape, so I replaced both front shocks as well. While I had everything apart, I inspected the wheel bearing assemblies, and they both seemed to be okay (also with the wheel on there is no play that might indicate faulty bearing). The grease inside was old (but I didn't find any shavings) so I cleaned them and greased them up. Brake pads are fine and the rotors are not warped nor do they have uneven wear or grooves. The CV joints do not have torn boots (I have not pulled them apart and inspected them yet).

I put everything back together and I now can do a tight turn again (turn wheel hard over and turn 360 degrees complete circle), but I still have the metal-on-metal noise. This noise always occurs on the inside wheel when turning (if I'm turning left, it comes from the left side wheel). I happens when I am in DRIVE, but does not happen in REVERSE. The noise is definitely not coming from anywhere near the transfer case.

Today I put the car up on 4 blocks (so all wheels were off the ground), took the front wheels off and put it in drive. No noise (other than the ABS... it didn't like to be high and dry). It only happens when the weight of the car is on front axle.

This is not a clunk/clunk noise that you might associate with a bad axle. My first instinct was to replace the bearings, but they don't exhibit any signs other than the noise but I would think I would hear the noise when driving straight as well. And the "inside wheel" and "DRIVE only" facts don't help either. I'd jump to replace the bearings if it wasn't for the $120 each price tag (and I don't like shotgunning).

So... any thoughts would be much appreciated!

Thanks, Mike

[Chris Stewart]

Try applying a tiny bit of brake pressure during your manuver to be sure the brake pad isn't dragging the rotor in a noisey manner.
Does the noise change with vehicle/engine speed?
Plenty of gear lube in the front differential?