SURVEY: Front Differential Problems

Wallrat · 01-26-2007, 07:30 AM

I've been having more and more problems with my front diff and I've read of several others who have as well. So if you've had an issue, even a minor one, please post it. Be sure to include year/model, big tow or not, lifted or stock, what happenned, what you were doing, and what the dealer did to fix the problem.

Wallrat · 01-26-2007, 07:44 AM

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.

d0va · 01-26-2007, 08:01 AM

that suxs sorry to hear that...

2006 CC 4x4 6000miles

Transfer case had loose bolts and was leaking oil.
Fix by dealership under warranty

bestatchess · 01-26-2007, 08:03 AM

2004 4x4 CC BT OR
DR coilovers, Deavers

front diff rebuilt once for bearing failure, then driver's side seal replaced for leaking, then front diff later replaced for C-clip axle shaft pulling out & internal grinding noise - all repairs under warranty

**Titan1080** · 01-26-2007, 06:22 PM

Quote:

Originally Posted by bestatchess

2004 4x4 CC BT OR
DR coilovers, Deavers

Then front diff later replaced for C-clip axle shaft pulling out & internal grinding noise - all repairs under warranty

Ditto for me, service guy said it will be under warranty. We'll see when the part comes in.

whiteLE · 01-26-2007, 06:25 PM

wallrat

Good stuff. If you want to start a log similar to the rear diff we are having, let me know and I can PM you on how to convert excel file to .pdf.

white

Justintoxicated · 01-26-2007, 07:45 PM

Damn man, I'm sorry to hear you had a bad experience in Mexico of all places... I hope the rest of your trip went well. Now you have had both your diffs replaced, and I doubt the lift really has much of anything to do with it... I mean sure yur running bigger tires, but come on! I wonder if your previous problems were just the result of something more resious (not like what the dealer told you). In fact i don't even understand what the dealer told you?

What is the stub shaft?

Wallrat · 01-26-2007, 08:29 PM

Basically your front wheels are turned by the front cv's, which in turn are bolted via 6 bolts to the stub shafts. The stub shafts have a 4" flange on one end (that bolts to the CV), and a shaft with splines and a groove for a c-clip on the other end. The splined end slips into the front diff and the c-clip snaps into a gap inbetween the splines on the inside of the diff to hold it in. Its a really crappy design, as it only takes a few pounds of force to pull out/push back in the shaft. Apparently mine seperated while under a load thereby twisting the splined end of the stub. That's my guess anyway.

Found a drawing on another post. #14 is the bastard stub shaft that I twisted. #16 is the stoopid clip that's supposed to keep your diff in 1 piece.

tt408 · 01-27-2007, 08:25 AM

front diff rebuilt once for bearing failure at
2200 miles

whiteLE · 01-28-2007, 10:51 AM

All,

Does anybody have a part number for their front diff/transfer case? I think it makes sense to track the front failures as Wallrat suggests, but we should have old/new part numbers at a minimum (NHSTA #'s would be nice as well).

thanks
white

As Fuzzy suggests to do below here:

Front Axle Snaps from Diff

Wallrat · 01-29-2007, 06:29 PM

Quick update:

Took my truck into Nissan of Garden Grove today - warranty denied again. Asked them what the reason was and they said that it was because its the same problem as last time so they defaulted to the same cause as well. I told them about rwhite's post:

Quote:

It is just a band-aid if they only replace the c-clip. I had my axles pop out. The first time the dealer said the c-clips were still on there, but they went ahead and replaced the clips and put new seals in. It happened again 2 weeks later, the dealer called Nissan and they are aware of the problem and said that the front differential must be replaced. They said it is redesigned. If anyone knows what they did to redesign it, it would be nice to know.

My tech said they called Nissan and there was nothing posted saying that a new Diff had been released or anything about this problem. Obviously something's not right here. So next I called 1-800-NISSAN-1 and filed a claim with them. Supposed to be getting a call back tomorrow. I'll keep everyone updated.

Herbpov · 01-29-2007, 07:03 PM

Quote:

Originally Posted by Wallrat

Quick update:

Took my truck into Nissan of Garden Grove today - warranty denied again. Asked them what the reason was and they said that it was because its the same problem as last time so they defaulted to the same cause as well. I told them about rwhite's post:
My tech said they called Nissan and there was nothing posted saying that a new Diff had been released or anything about this problem. Obviously something's not right here. So next I called 1-800-NISSAN-1 and filed a claim with them. Supposed to be getting a call back tomorrow. I'll keep everyone updated.

Their reply will most likely be: " Never seen this before " Heard this many times when I've called them. They make it sound as if I'm the only one with a problem. VERY UNPROFESSIONAL !!!!!

Wallrat · 01-29-2007, 07:30 PM

Yeah I hear ya. This is my 3rd Nissan and the only one I've had issues with - and boy have I had some issues! The most frustrating part has been the constant uphill struggle with the dealerships. I'm torn as to whether I should drop a bunch of money into a custom drivetrain or just sell the truck and buy $42,000 worth of duramax troubles.

Justintoxicated · 01-29-2007, 09:00 PM

Seriously I'm starting to think y ou should cut your losses and sell it, Hell you almost have me to the point where i want to sell mine. I just can't afford to sell mine...

Wallrat · 01-30-2007, 06:10 PM

UPDATE:

So I got a call from Jim at 1-800-NISSAN-1 today (nice guy btw so be cool to him if you ever have to call there). Anyway he just did a follow-up so he could try to get me in touch with the regional field rep in the next day or 2. That rep is actually the reason why I've been having so many problems with this.

Back when I first had the problem, I took it to Douglas Nissan on Beach Blvd. They weren't sure if they should cover it or not so they asked the field rep who just happened to be there for a different vehicle. He denied my claim based on the tool marks on the 6 bolts on the CV/stub shaft. Those bolts are removed to PROTECT the stub shaft when the knuckle is removed during the installation of the lift. Unfortunately this guy must not know this. The rep was gone by the time I got there and the service manager there accused me of fraud when I tried to point out the error in the rep's logic (long story). Took it to Nissan of GG instead and they couldn't do anything since work order specifically stated what the rep said. I didn't fight it much at the time since it was only gonna cost me $300 - BIG MISTAKE!

So I'm stuck in this rut where the dealerships can't fix my diff under warranty because this guy told them not to on 12/6/06. So I picked up my truck today, and paid the $97 bill for the "estimate" (which comes out to $3500 btw, not including the $97). I was wondering what a $97 car wash would look like but then they didn't even wash it!