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Old 01-26-2007, 08:44 AM   #2 (permalink)
Wallrat
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Re: SURVEY: Front Differential Problems

I'll start things off:

05 KK w/ BT
6" Pro Comp Lift (went on before summer of 06, no problems since)
35" tires
35,000 miles

12/06 - noticed front diff was leaking on drivers side stub shaft. Dealership said that the lift caused the wheels to turn too far thereby seperating the shaft. Not warranty, cost me $300 to repair because seal was torn.

3 weeks later - Stub shaft seperated again, despite the new steering stops that I've welded on making U-turns in average intersections impossible. This time I just pushed it back in and the leak stopped.

Last week - 4x4 on a beach in Baja. Wife is driving truck in a straight line down the beach following me while I'm kiteboarding in the water (I'm 100% sure that there were no leaks 10 minutes before). I hear a loud bang come from the truck, and I'm out in the water! I come in and find the driver's side stub shaft completely pulled out and a big oil puddle. Try to push it back in but it won't go. Wife isn't sure if she was in drive or reverse (she's freaking out and crying btw). Luckily its less than a mile to the place we're staying so I get towed off the beach. End up pulling front diff cuz stub shaft WILL NOT go back in. Discover that stub shaft has twisted the entire length of the splines - that's 1" solid steel folks! Ended up having to hammer it back in (thereby destroying the splines) in order to make it home. Didn't leak though. Going to the dealership today to find out how screwed I am.
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I've got feeler gauge fingers, torque wrench wrists, and a timing light eyeball!

05 SE KK 4x4
offroad, big tow, buckets, util.
$$$ stereo
Pro Comp 6", Dre's/Bilsteins, PRG Traction Bars
315/70 17 BFG AT KO on 17x9 AR Chambers

Last edited by Wallrat; 01-26-2007 at 09:11 AM.
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