Noise from front diff/ transfer case after gear install

[818Gladiator]

Because I was so adamant/ firm that it was not the transfer case, the shop continued to look into the truck. And they went as far as removing the front driveshaft and manually engaging the front diff through the FAD. Because I made the comment about the pinion depth. Removing the driveshaft they noticed the damage. And they still went ahead and did the test to ensure at THIS moment there is nothing wrong with the front gear install.

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[Badunit]

Why do they need to rip into the rear diff to replace the rear driveshaft? It unbolts from the diff.

 

[818Gladiator]

They change the output shaft on the diff, not 100% sure that’s the name. Im bad with names, it’s a problem as a full grown adult.

 

[818Gladiator]

I understand that the way I drive the truck is the reason this happened. I do not bash my truck on the rocks, but the extreme angles the truck goes through cresting a sand dune, when the front wheels leave the ground, and being on only 1 wheel and a de-beaded wheel and bouncing off redline “probably” did the majority of the damage and I don’t want to be left stranded out in the dunes or out in the snow cuz of my rear driveshaft failing due to a similar situation. The front had to be done and it just bolts in, I am doing the rear as a precaution

 

[818Gladiator]

I appreciate everyone’s suggestions and help. I believe my issue is resolved. Thanks for all the info​

 

[pcrawfordpt]

They change the output shaft on the diff, not 100% sure that’s the name. Im bad with names, it’s a problem as a full grown adult.

Yes…they need to replace the yoke, not inside the diff, but going into the diff. The new driveshaft uses a more standard u-joint yoke.

 

[CrazyCooter]

Yes…they need to replace the yoke, not inside the diff, but going into the diff. The new driveshaft uses a more standard u-joint yoke.

If the OP wants the installation of the replacement yoke done by the book, the crush sleeve on the pinion shaft needs replaced and that requires a complete gut of the differential housing to properly set bearing preload.

I've been successful over my career at replacing pinion seals and yokes without doing the full gut saving the client some serious $$$, but it is not 100% by the book and does come with a certain amount of liability.

 

[pcrawfordpt]

If the OP wants the installation of the replacement yoke done by the book, the crush sleeve on the pinion shaft needs replaced and that requires a complete gut of the differential housing to properly set bearing preload.

I've been successful over my career at replacing pinion seals and yokes without doing the full gut saving the client some serious $$$, but it is not 100% by the book and does come with a certain amount of liability.

Good to know…just never known of anyone going to that extent when replacing the yoke for a new driveshaft.

 

[818Gladiator]

Yes exactly crazycooter. Since I have to pay a small amount of labor, as shop is being cool. I have ordered a Ox-locker for the rear differential and will have him put that in also, so I won’t pay labor a 3rd time in the future. Shop is charging $400, I think in CA that super reasonable.

 

[CrazyCooter]

Good to know…just never known of anyone going to that extent when replacing the yoke for a new driveshaft.

Honestly this whole situation is a train wreck looking for a place to happen.......

The shop did an install of customer supplied parts. In a post on page 1 he said the shop was handed a full set of gears, but no mention of master install kits. Then there was a question of a possible warranty in workmanship. Now they need to replace the yoke.......

Here in CA, the shop is on the hook for the warranty of the entire job regardless of who supplied the parts. At my shop I either do the entire job, parts and labor so that I can offer a complete warranty no questions asked (barring abuse or other exclusions).

I also feel that a god tech would have spotted the leaking boot on the cv and should have sold a replacement driveline at the time of the gear job?

 

[818Gladiator]

Honestly this whole situation is a train wreck looking for a place to happen.......

The shop did an install of customer supplied parts. In a post on page 1 he said the shop was handed a full set of gears, but no mention of master install kits. Now they need to replace the yoke.......

Here in CA, the shop is on the hook for the warranty of the entire job regardless of who supplied the parts. At my shop I either do the entire job, parts and labor so that I can offer a complete warranty no questions asked (barring abuse or other exclusions).

I also feel that a god tech would have spotted the leaking boot on the cv and should have sold a replacement driveline at the time of the gear job?

 

[818Gladiator]

Driveshaft was fine when it was put in. It broke when I put the truck in 4WD on the street AFTER gear install. They were provided with an install kit for gears. They will be provided with a NEW install kit again for the OX-locker.

 

[CrazyCooter]

Driveshaft was fine when it was put in. It broke when I put the truck in 4WD on the street AFTER gear install. They were provided with an install kit for gears. They will be provided with a NEW install kit again for the OX-locker.

Good on the driveline situation......The Rzeppa joints sound much like a pinion bearing when they fail.

Again.....my point of view from a business owner's standpoint.......This has way too much negstive potential to be involved with. I just dont see the point in doing a transaction where I assume all the liability while making less money to cover a potential issue? This shop is losing big in this job.

 

[Escape.idiocracy]

If the OP wants the installation of the replacement yoke done by the book, the crush sleeve on the pinion shaft needs replaced and that requires a complete gut of the differential housing to properly set bearing preload.

I've been successful over my career at replacing pinion seals and yokes without doing the full gut saving the client some serious $$$, but it is not 100% by the book and does come with a certain amount of liability.

^^ truth. I have heard of folks changing without replacing? But I don’t know how preload is maintained on the pinion bearings then. ? nuts, but I don’t think it’s really “that” big of a pain to just pull the carrier and do it right ??‍ beats having to do a master overhaul down the road.

 

[818Gladiator]

I would have gladly purchased all my parts from the shop. But as a consumer I also have to find the best ways to save. It was cheaper for me by about 15% to buy my parts direct from manufacturer. I can’t say as to the business practices of the shop. However they have been in business for over 20years, it’s a pretty nice shop, they have to be doing something right id imagine.

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