Angie2004Expy, YES! I did finally fix the issue...less than two weeks ago. It took so long because I simply could not have my expy off the road at all until this past month. I've been working on an update, saving my unfinished post in my documents. It's very difficult for me to type/read much because of a fast-growing cataract, which will be surgically removed next week. After that, I SHOULD be able to see properly again.
Anyway, Per my previous posts, the sound was coming from the front driver side tire area...along with ever increasing vibration, etc. As posted, I replaced that bearing/hub assembly with various manufacturers bearings, two of which WERE defective due to grease seals blowing out almost instantly (MOOG's) Finally ended up with a TIMKEN hub assembly, which didn't solve the issue but I knew it was a quality part.
My front struts were worn, having been replaced over 100,000 miles ago. I needed new upper ball joints/control arms as well. I had replaced lowers last year (DO NOT buy/use MOOG "PROBLEM SOLVER" ball joints! The grease seals don't fill/expand like they are supposed to, they simply spew/leak grease everywhere) So, I FINALLY installed new KYB Excel-G struts as well as new springs (AC DELCO's) and KYB strut mounts. I installed new upper control arms/ball joint assemblies and new inner tie rods (replaced outers last year).
NOW, we get to the surprising discovery. While working on the front suspension, I had removed calipers to get that weight off spindle assemblies & allow me to drop the lower control arms far enough to remove/install struts. BTW, I installed the strut assemblies (springs, top mounts & bellows) individually, then, used my floor jack under lower control arms to compress the springs into the upper mounts. Those springs are far too heavy-duty for any of the usual spring compressor tools I tried, and I tried several. Local shops wanted $80.00 just to assemble all new parts, no disassembly involved, BUT, would not guarentee not to use air tools/impact gun to secure shaft to top mount. I didn't need my new struts having inner seals getting hot/damaged from some cowboy with an impact gun....so.
Here's the thing, it was actually safer by far, installing like I did, than using any spring compressor tool! At no time did the spring ever try to POP! and fly out from under the vehicle, it compressed perfectly in it's seat...hardest part was making sure it was in proper position in relation to the upper seat, and, making sure the bellows stayed in place until spring was seated.
The reason the compressors couldn't get the job done & required a bench mounted style "press" is because the KYB Excel-G struts have an internal anti-rollover spring. This prevents the strut shaft from reaching its full length which in turn means the spring must be compressed at least twice as much so the threaded part will reach & get through the upper mount. I was doing some work on the expy several months ago, when the idea struck me to see how much the weight of the vehicle compressed the springs. Upon inspection, I clearly saw it was enough to at least attempt my idea....so, I did. It worked like a charm, HOWEVER, just to be sure, I DO NOT recommend anybody attempt this procedure so as to prevent personal injury, or worse.
Anyway, after removing the caliper on the passenger side, and, mind you, I had previously inspected this side several times last year, the bearing was smooth & no grease leakage. Now, however, it was dry/rough sounding, but still, no grease leakage. None, at all. When I spun the rotor, not only did the bearing sound terribly rough, not metallic rough, more like dry/sandy rough, but, it was causing the dust shield to vibrate....WOW!
I finished the suspension work, after running inside to order a TIMKEN hub assembly for the passenger side. In the meantime, I had to use the expy while waiting for my new hub assembly to arrive in two to three days from Rock Auto.
Now, with the new struts, springs, control arms & inner tie rods, the noise/vibration actually switched over to the PASSENGER side...where the ACTUAL faulty bearing was/had been, all along! Also, the noise/vibration was nearly 90 % GONE and was only present when I made right turns. When the new hub assembly arrived, I installed it & everything is as it should be...quiet & rides like new again!
My expy is rear wheel drive, not 4x4 which I believe yours is? However, how many miles are on your struts assemblies? IDK HOW the noise/vibration was transmitted from the right to the left side, I know WHY it was making the noise, just fooled me all this time by appearing to be on the driver side. So, maybe use my experience here to hopefully help solve your issue....let me know if I can be of service, but, I'll only be on here & there until I get my cataract removed. GOOD LUCK to you!!
