[whincup]

last night i was cruising along the highway, doing about 90km/h... all of a sudden it felt like someone had tapped the brakes, car dropped to about 70km/h... then came a rattling-grinding noise... pulled over and took a look, theres LOTS of oil coming out from around where the rear driveshaft joins to the transfer case. i decided to try driving slowly with my head out under the car to see if thats where the noise was coming from... and im fairly sure its the rear diff.

its at the mechanics now, they're going to have a look at it monday or tuesday, but would anyone have any ideas as to what went wrong?? the colour of the transfer case oil was the same honey color as when it went in 9 months ago.

to me, the noise sounds like a gear, or a piece of metal has come loose inside somewhere and is being flicked around by other moving gears... but the car still moves under its own power, just noisy...

[redzook91]

maybe bearings let go? what's the noise like, grinding or rattling or what?

[lump_a_charcoal]

whincup wrote:

theres LOTS of oil coming out from around where the rear driveshaft joins to the transfer case.

Start here.

Take out the Tcase, drain the oil that's left and watch for debris.

Also, try turning it by hand, through all the gears

Check for play in the output shafts too.

[whincup]

theres plenty of play in the rear shaft, but there always has been a fair bit. I always assumed that was from wearing and old age, but normal...

the noise is a kind of grinding/clunking... or a heavy grinding... to me it just sounds like theres a chunk of metal being swirled around inside a case somewhere, being spun and rubbed up against another spinning gear... if that makes sense, sorry im not much good at descriptions...

[lump_a_charcoal]

Sorry I meant side to side play, not rotational.

[31zook]

I would very carefully jack up the rear tyres (on stands), start the motor and put it in 1st low, climb in underneath from the back (not in front of the rotating tyre)and listen. If oil is pumping out of the Tcase then it's more then likely that, but if you have an open diff then spin them with your hands and make sure they spin opposite directions. with out any clunking.

[whincup]

i did check the shafts first, because initially i thought a u-joint had let go. got under and gave the jackshaft and rear shaft a good yank, and nothing out of the ordinary... mechanics will let me know whats up, its there at the moment, i doubt these blokes will try to bullshit me... guess i find out monday or tuesday

[whincup]

ok so ive just been out there for a listen... i put it in 2nd gear high range wheels jacked off the ground... and the sound is absolutely HORRIBLE. if i hold the rear shaft still and spin the wheels, the sound goes away... the shaft is fine, the u-joints are fine, but when i spin the shaft i can feel it skipping somewhere, almost as though its stripped a few teeth inside the diff... is this possible to happen while highway driving?? happened while doing about 90km/h

[lump_a_charcoal]

My diff let go when I was driving, but it stopped me pretty quickly!

[whincup]

...well i just drove it home about half hour ago. didnt leave first gear, just took it slow...

also, what is the best kit to fully rebuild the diff centre, with or without gears as i could probably get them separately...

and whats the best cheap without going crappy auto locker? while its apart, i may as well throw one of those in...

[Fatzook]

whincup wrote:

...well i just drove it home about half hour ago. didnt leave first gear, just took it slow...

also, what is the best kit to fully rebuild the diff centre, with or without gears as i could probably get them separately...

and whats the best cheap without going crappy auto locker? while its apart, i may as well throw one of those in...

If the diff bearing have collapsed, your gears will be FUBAR. So you will need a complete diff centre to replace it with.

As for the locker, ARB is the only thing better than auto locker. Actually I'd preffer a jar of iSnack 2.0 in my diff than an auto locker, but whatever.

[whincup]

...i dont have the money for an air locker, auto locker will be fine for the rear diff. would never consider it for the front, but whats the best value for money for a daily drive/weekend toy? and can you get new gears in stock ratio's?

[Fatzook]

whincup wrote:

can you get new gears in stock ratio's?

no.

[whincup]

Fatzook wrote:

whincup wrote:

can you get new gears in stock ratio's?

no.

thats crap. hopefully its just the bearings then...

[lump_a_charcoal]

Just buy a centre from a wrecker, and make sure it looks good.

BTW I'd preffer a jar of iSnack 2.0 in my ass than an auto locker, but whatever.

[whincup]

lump_a_charcoal wrote:

I'd preffer a jar of iSnack 2.0 in my ass than an auto locker, but whatever.

ive always wanted to go with an air locker, but never had the money for it. or an auto one either for that matter, because i have no idea how to install it. but since i have to pull my diff apart anyway, i may as well put one in...

has anyone had any good experiences with an auto locker, such as detroit or lockright, or other brands...?

btw, local wreckers only have sierra shells with either roll damage or massive rust... theres bugger all left of them

[want33s]

I've sent diffs to tassie for less than $40.

[whincup]

want33s wrote:

I've sent diffs to tassie for less than $40.

well after how the jackshaft i bought off u went last time, you were first on my list to ask, right after i checked out local areas. i just dont have the coin for it right now, and im waiting for the weekend to be 100% sure this is the problem... do you have any WT diffs with the 3.7 ratios?

[paulv]

want33s wrote:

I've sent diffs to tassie for less than $40.

who do you use for freight?

[whincup]

am told by a mechanic mate, who came and had a listen, the bearings are, to quote, "completely f**ked", and gears MAY have damage, but the fact that it skips every now and then tells me ive stripped a tooth or two... im going to attempt replacing bearings/seals, etc, myself, and if i stuff it up then i will ask around local shops... il take a look at gears when its out... while its out i figure i may as well throw in a locker... is it possible for someone who's never done this sort of thing to do properly?? going to go for this one: http://locktup4x4.com.au/suzuki-sierra- ... r-271.html

also, transfer case has always had a very minor leak from somewhere, enough to notice, but never enough to worry me... the seal around the rear shaft output is leaking really bad now too, so im going to pull that out and redo all the seals/bearings on that too... going to use the locktup kit, but from what ive been reading from old threads its missing a few essentials. my case makes no noises, and since replacing the gear shifter seal, or whatever its called, its been smooth, so other than the leaks its in vgc, is all the other stuff necessary?

[Fatzook]

You shouldn't attempt the diff if you have no idea what you are doing. To lap a diff and set backlash properly takes a bit of practice, some feeler gauges, lapping paste and knowledge.

For this reason I give mine to someone else to do.

[lump_a_charcoal]

If you have never set up a diff before, then I would say no, get a pro to do it.

The problem with autolockers is that if they are not set up 100% right, they become reallllly fucking annoying.

Remember to get a new crush tube too.

[whincup]

ok then... if done professionally then i cant afford the locker. so that aside (probably better anyway, save for an air locker sometime in the future) how much would i save if i pull out the diff centre and take that to a shop over taking the whole car there?

[Merk]

This is a bit of a grave dig, but i figured it's better than starting a new thread.

I'm having a very similar issue with my front diff at the moment, so I'm wondering if you got this sorted and how you went about it.

I'm pretty sure you live in the same town as me, so if you did get it fixed at a shop, could you let me know where you got it done and if you'd recommend them?

[whincup]

i ended up getting a used one, makes a bit of noise but works fine. i still have my original, just not repaired... everywhere i asked quoted over $500. i did all the removal/fitting myself without knowing what i was doing, except bleeding the brake lines... still dont know exactly whats wrong with the diff centre, but all the gears look good so im assuming stuffed bearings. may get it fixed one day when i get a locker...

most people i asked around the area suggested andy's auto repairs for $540, but i cant remember if that was taking the whole car there or just the diff centre...