Front differential blows

spyderwebb · 01-15-2007, 08:43 AM

Hey guys, been some time since I posted on here, but wanted to share my story (bad luck) and get some input from the forum. Yesterday while driving in the snow, only about 2 inches, in 4H, my front differential went boom and cracked open. I've had the truck since new (09/04) and have only had it in 4WD about half a dozen times. Of course it began dumping differential fluid all over the place. Crawled up underneath it and it was split like a cracked egg.

I have 59,833 miles on her (2004 King Cab SE) and I have always taken really good care her. Called the Nissan shop today and they seem pretty reluctant to suggest it was a covered issue. Said they have no history of any problems like that, probably think I did something negligent to cause it. From my research on this site, it has happended at least 5 times that I can find, but generally while towing something in reverse. I can guarantee they are going to have a fight on their hands. I was was just moving forwardat about 5 mph, can't explain what might have caused it other then maybe the gears got out of mesh due to some sort of flaw and popped out of place. I'm waiting for the tow truck to haul it to the Nissan shop, will take some photos and post for all to see, in the next hour. Any advise, suggestions or comments are really appreciated.

**konigfritz** · 01-15-2007, 08:51 AM

Strange! ARe you running stock size tires and wheels. if not they may give you the run around. Sounds like it may have bound up for some unknown reason. Good luck.

spyderwebb · 01-15-2007, 09:02 AM

Yep, stock tires just replaced them with OEM bought from the Nissan dealership about 6 month ago. I have only added Banks Cat Back Exhaust and OEM Brute Force Intake.

Herbpov · 01-15-2007, 09:15 AM

Quote:

Originally Posted by spyderwebb

Hey guys, been some time since I posted on here, but wanted to share my story (bad luck) and get some input from the forum. Yesterday while driving in the snow, only about 2 inches, in 4H, my front differential went boom and cracked open. I've had the truck since new (09/04) and have only had it in 4WD about half a dozen times. Of course it began dumping differential fluid all over the place. Crawled up underneath it and it was split like a cracked egg.

I have 59,833 miles on her (2004 King Cab SE) and I have always taken really good care her. Called the Nissan shop today and they seem pretty reluctant to suggest it was a covered issue. Said they have no history of any problems like that, probably think I did something negligent to cause it. From my research on this site, it has happended at least 5 times that I can find, but generally while towing something in reverse. I can guarantee they are going to have a fight on their hands. I was was just moving forwardat about 5 mph, can't explain what might have caused it other then maybe the gears got out of mesh due to some sort of flaw and popped out of place. I'm waiting for the tow truck to haul it to the Nissan shop, will take some photos and post for all to see, in the next hour. Any advise, suggestions or comments are really appreciated.

Said they had no history of any problems like that. That seems to be Nissan answer to everything. Gave me the same answer when I called about the rear axle seals leaking. I've got the same truck as yours.

**walleeme** · 01-15-2007, 09:37 AM

Doesn't he have a 5 year, 60,000 mile pwertrain warranty?
My buddy just got a new front diff in a 2006 CC SE OR BT at 25000 miles.

spyderwebb · 01-15-2007, 10:44 AM

Here are a few pictures of the damage on the front differential

SKEET · 01-15-2007, 10:46 AM

Your still under the milage so tell them to fix it and stop complaining.

spyderwebb · 01-15-2007, 10:53 AM

That's my game plan

spyderwebb · 01-15-2007, 01:09 PM

Good news, the Nissan shop just called and said that they will cover it. They asked if I had been jacking around, which I wasn't. The service manager said "they haven't seen that happen under normal 4wd use". It appeared that the ring gear had just jumped out of place and cause the housing to split. Which he suggested happens when someone is out putting a lot of stress on the system in heavy 4wd use. The only thing I did was put it in 4 wheel low for a test, about 20 feet and then back to 4 wheel high, following all proper procedures, as identified on the sun visor, also the surface I was on was completety snow covered (about 2", and some area were 4-5" drifts & piles, no dry spots.

Fortunately, I also purchased the Silver Extended Warranty, this covers me up to 75,000 miles and provide up to 4 days of rental car coverage, that is about how long he said it will take to fix. He is ordering the new front differential from Nissan today.

I obviously am pleased that this is going to be covered, but also very concerned that this kind of thing is capable of happening.

Good luck to you all with your Titans, I have loved this truck, even in light of the brake problem (dealer fixed under warraty, new rotors, etc.), AC leaking on floor matt problem, which cost me $140 to fix, because of a desing flaw that clogged in the drain system which was unfortunately not a covered component, and an annoying ticking sound coming from under the front passsenger area whenever a load was put on the engine in normal driving situations. They finally found the source of the problem and fixed under warranty, took three trips to the dealership for that one. Finally, a problem with the fuel guage which they tried to fix but still does the same thing, doesn't always go to full after fill up, stays about an 1/8 below the full mark.

Anyway I continue to be proud of this truck and support the quality of design and build, Honelstly however, I thinking it might be time to look into a new Tundra????

Titanminator · 01-15-2007, 01:09 PM

Quote:

Originally Posted by spyderwebb

Hey guys, been some time since I posted on here, but wanted to share my story (bad luck) and get some input from the forum. Yesterday while driving in the snow, only about 2 inches, in 4H, my front differential went boom and cracked open. I've had the truck since new (09/04) and have only had it in 4WD about half a dozen times. Of course it began dumping differential fluid all over the place. Crawled up underneath it and it was split like a cracked egg.

I have 59,833 miles on her (2004 King Cab SE) and I have always taken really good care her. Called the Nissan shop today and they seem pretty reluctant to suggest it was a covered issue. Said they have no history of any problems like that, probably think I did something negligent to cause it. From my research on this site, it has happended at least 5 times that I can find, but generally while towing something in reverse. I can guarantee they are going to have a fight on their hands. I was was just moving forwardat about 5 mph, can't explain what might have caused it other then maybe the gears got out of mesh due to some sort of flaw and popped out of place. I'm waiting for the tow truck to haul it to the Nissan shop, will take some photos and post for all to see, in the next hour. Any advise, suggestions or comments are really appreciated.

Nissan is going to replace my front diff and transfer case due to a humming sound during 4H. I dont tow anything backwards, but I do back my boat into an incline with gravel driveway. I have 48K and they said that the warrany will cover. Good Luck to you.

Herbpov · 01-15-2007, 01:37 PM

Quote:

Originally Posted by spyderwebb

Good news, the Nissan shop just called and said that they will cover it. They asked if I had been jacking around, which I wasn't. The service manager said "they haven't seen that happen under normal 4wd use". It appeared that the ring gear had just jumped out of place and cause the housing to split. Which he suggested happens when someone is out putting a lot of stress on the system in heavy 4wd use. The only thing I did was put it in 4 wheel low for a test, about 20 feet and then back to 4 wheel high, following all proper procedures, as identified on the sun visor, also the surface I was on was completety snow covered (about 2", and some area were 4-5" drifts & piles, no dry spots.

Fortunately, I also purchased the Silver Extended Warranty, this covers me up to 75,000 miles and provide up to 4 days of rental car coverage, that is about how long he said it will take to fix. He is ordering the new front differential from Nissan today.

I obviously am pleased that this is going to be covered, but also very concerned that this kind of thing is capable of happening.

Good luck to you all with your Titans, I have loved this truck, even in light of the brake problem (dealer fixed under warraty, new rotors, etc.), AC leaking on floor matt problem, which cost me $140 to fix, because of a desing flaw that clogged in the drain system which was unfortunately not a covered component, and an annoying ticking sound coming from under the front passsenger area whenever a load was put on the engine in normal driving situations. They finally found the source of the problem and fixed under warranty, took three trips to the dealership for that one. Finally, a problem with the fuel guage which they tried to fix but still does the same thing, doesn't always go to full after fill up, stays about an 1/8 below the full mark.

Anyway I continue to be proud of this truck and support the quality of design and build, Honelstly however, I thinking it might be time to look into a new Tundra????

WHAT ???? FOUR WHEEL DRIVE NOT FOR HEAVY USE. RING GEAR JUST JUMPED OUT OF PLACE.

bestatchess · 01-15-2007, 01:41 PM

"It appeared that the ring gear had just jumped out of place and cause the housing to split."

WTF? Sounds like B.S. to me. The ring gear is bolted to the carrier. The carrier is supported for rotation in the housing by carrier bearings. The carrier bearings are held by bearing caps bolted to the housing. The ring gear does not jump anywhere unless the housing, the carrier, the bearing caps, the bearing cap bolts, or the ring gear bolts fail first. In other words, I think it is likely that the housing failed causing the ring gear to move out of place, not vice versa.

bestatchess · 01-15-2007, 01:45 PM

Front diff exploded view from service manual is here:

Request for Front Differential Exploded View

Note ring gear 30, side bearings 2 and side bearing caps 31. They have 27 & 29 swapped/mislabeled in the drawing. 27 actually points to the housing/case and 29 actually points to the carrier.

spyderwebb · 01-15-2007, 02:01 PM

Thank you for that techincal correction. All I know is something jumped the heck out of place and bada bing bada boom, all the king horse and all the kings men could not put humpty together again.

Your right, from looking at the expoded version of the differential, your interpretation of what happened is obviously correct.

bestatchess · 01-15-2007, 02:40 PM

I am thinking either the bearing cap(s) failed or the housing failed. The tech that took it apart would know.