PRG leveling kit and Front axle strain

[rwhite]

Has anyone had problems with the PRG kit on 4wd Titans? I was in snow the other day with the truck in 4wd, and the wheels turned to full lock. I must have hit some solid ground because I heard a pop, and my front axles popped out and drained the fluid. Is the leveling kit such that it causes the axles to ride against the circlips at full wheel lock? The dealer said that the clips were still on the axles, and they popped them back in. By the way I took off the kit prior to taking it in for warranty work. I'm just wondering if I should put it back on and risk it doing it again. The kit was on for 2 years prior to this happening with no problems at all. Any help would be helpful, Thanks.

[bestatchess]

My front diff was just replaced under warranty. I have the DR coilovers and did not take them off. Others have had the same problem with stock front suspension (search for akangl posts as one example). Some people have had them pop out while installing the leveling kit.

I think maybe the C-clips axles just suck, or maybe the C-clips are too small. I know if you mention C-clip axles (Dana 35C) to hard core Jeepers, they get a terrified look on their face and start whimpering. Threaten them with an aluminum housing C-clip differential (ZJ Dana 44) and they suck their thumb and grab their fuzzy blanket.

Several people have posted here about the (aluminum housing) front diff breaking into little pieces when they try to pull something (e.g. another stuck vehicle or a stump) in reverse.

I'm beginning to think that the front diff is a design defect, but I would love to hear from somebody with alot of knowledge and experience. (e.g. PRG). BTW, I think PRG bought a 2WD.

[PrerunnerGreg]

The axles popping out is a pretty common problem on all titans and armadas, lifted or not. For some reason cold weather has somehting to do with this issue (wether it is the cold or just people using 4wd, im not sure). The circlips that retain the axle shafts fail or are undersized, usually the dealer will replace the complete front axle assembly. Again, it has nothing to do with any lift, as many, many stock trucks have this issue. Just one more thing nissan needs to add to the "fix it" list.

[Herbpov]

Originally Posted by PrerunnerGreg

The axles popping out is a pretty common problem on all titans and armadas, lifted or not. For some reason cold weather has somehting to do with this issue (wether it is the cold or just people using 4wd, im not sure). The circlips that retain the axle shafts fail or are undersized, usually the dealer will replace the complete front axle assembly. Again, it has nothing to do with any lift, as many, many stock trucks have this issue. Just one more thing nissan needs to add to the "fix it" list.

Great, just another thing I have to look forward to. First the rear end and now the front. Just don't trust this truck anymore. Got to start looking eslewhere.

[rwhite]

Well the dealer said that the clips were still on the axles and not broken. I hope that is the case and they didn't just leave the broken clips in the differential and put new ones on. I guess I have no way of really knowing. I have to go pick it up in a few hours so I'll tug on the axles and see if they still pop out. It seems to me that the longest extension the axles get is when they are at full wheel lock. At that point the CV joint must be fully extended and the clips have pressure on them to make them pop. I will have to investigate further when I get it back.

[Wallrat]

I had no problems for 24k miles and then put a 6" lift on. Still didn't have a single problem until 10k miles later when my driver's side CV popped out and damaged a seal in the process. Dealer said that it was because the wheels were turning too far with the lift on so I ended up having to pay $300 for the work. I welded on some new steering stops that limit my turning radius to ridiculously large (can't make a U-turn in anything less than a very large intersection). Few weeks later, same thing happens again. This time however, the seal is fine and I'm able to just push the CV back into the diff. Another month goes by and I end up stranded in Baja - same problem, but this time on the way out the shaft actually got twisted! The clip was fine but the splines won't mesh anymore so the only way I can get my happy butt stateside is to beat the thing back into the diff with a BFH. Of course I didn't discover this until after I pulled the whole diff out in a dirt parking lot. I'm gathering posts now so when I go to the dealer on Monday I've got some ammunition.

Seriously I have no luck with this truck. First the brakes, then the rear diff, now round 2 on the front diff.