This should make you go "WHAT THE Crap"

indynewfie · **Posted:** Sun Jan 22, 2006 8:53 pm

Alright i just got back from my "offroad weekend" and as i forgot my digital camera, I am waiting on my buddies to send me pics, which I will post here when i get them.
Long story short didn't get to do much off-roading. An hour into the day, climbing a 40 foot incline, of about 30-40 degrees (icy/snowy), half way up, in 4LO, feathering the gas ... my front diff casing BLEW OPEN. Oil everywhere and the shaft and pinion coming from the transfer case was on an angle, pinion end about 4-6 inches from where it should be.

Didn't hit anything, just trying to get up a hill, spinning tires a little on ice, and as soon as i let off the gas, BOOM. basically the top third of the housing cracked off, about a foot long section.

I have no idea how this would happen. If anything would let go in an axle one would expect the front shafts, or pinions or something to go. How weak is the Aluminum casing for IT to be the first thing to blow. Bad cast? I don't know. But I would really like to know if anyone else has experienced problems with the front diff like this.

Thanks

Skyjump136 · **Joined:** Tue Jul 05, 2005 6:50 pm **Posts:** 1633

Unfortunately...not too uncommon. :roll:

This usually happens when your front wheels are spinning and then "catch" on something solid.

jpzkj · **Posted:** Sun Jan 22, 2006 9:17 pm

Kinda look like this ?

Jeepjeepster · **Posted:** Sun Jan 22, 2006 9:23 pm

I believe this is only the 3rd or 4th on this site to have this happen. Sad story.

indynewfie · **Posted:** Sun Jan 22, 2006 9:33 pm

so is jeep aware of this weak point in the front diff? will they simply replace it with another aluminim cast diff or can you request a cast iron?

JJsTJ · **Posted:** Sun Jan 22, 2006 9:35 pm

jpzkj wrote:

Kinda look like this ?

That one right there is mine from over a year ago. I was cruising through a ravine with alternating high/low sides, causing the tires to keep being crossed up and I had a little wheel spin which I stopped via a light brake application. Went to give it a little more gas after it stopped spinning and Boom. Split open like a melon. Weak casting/factory flaw is what I say. I have seen many others spin and grab way worse that anything I even came close to doing when mine went. Other person in our group who blew his up was climbing a loose sandy hill at a pretty good angle when his went, almost exactly the same break pattern as mine in pic above.

SFA time. :wink:

Eddo · **Joined:** Thu Jul 07, 2005 7:01 pm **Posts:** 1214

indynewfie wrote:

so is jeep aware of this weak point in the front diff? will they simply replace it with another aluminim cast diff or can you request a cast iron?

They probably know about it but it is probably not financially worth it to fix. No cast iron available. And it's 50-50 if they will even replace it under warranty. Apparently off road and lifts are considered abuse, some dealers will repair it under warrenty some won't. BTW, I would like to see some pictures if you have any.

indynewfie · **Posted:** Sun Jan 22, 2006 11:17 pm

Right side of casing missing. Pinion exposed and ajar.

Parts (csing pieces and pinion teeth smashed)

KJ04 · **Posted:** Sun Jan 22, 2006 11:18 pm

Sorry to hear your bad luck.... Been there, done that!
Just when I was beginning to think the problem was a few bad castings, I up and blew mine. Front end jumped up and came down spining, boom oil all over. Then, $300.00 for towing to get it home. Ouch!
Dealer left me hanging for a day till they called some regional drive train office in Detroit about it. Detroit said they had no reports of failures so warranty was denied, do to off-roading.
Picked up a housing from a bone yard for $531.00 with the carrier and installed it myself.

Mine blew on the drivers side, that is the first one I've seen blown on the passenger side.

indynewfie · **Posted:** Sun Jan 22, 2006 11:30 pm

Alright, this sounds like it is a common enough problem that i think we should get a count of cases and take it to Jeep.

The last post says that our fellow KJer had to dish out over $500 for a used part and install it himself because "Detroit" has no reports.

Time we report it then, eh?

Is there anything that someone here thinks we can do?
We should at least report it officially and start some investigation into it.

If all it takes is a bit of whell spin up front that catches traction and BOOM! then this would still affect the average grocery-getting mom in winter going over the partially snow covered parking lots, let alone those of us who use the 'Trail-Rated" vehicle on a trail.

ShadE · **Posted:** Mon Jan 23, 2006 12:03 am

how was the trip home? any problems?

SunDvl · **Posted:** Mon Jan 23, 2006 12:32 am

I would think you could report it to the same department (NTSB or something like that) as the ball joints. If enough failures are reported this way, they will force Jeep to look into the issue - eventually.

jpzkj · **Posted:** Mon Jan 23, 2006 12:58 am

Jeep knows about it....They read our post's too.

Sorry to hear of your bad luck...check the dealer and the boneyards at the same time, it will save you some time while you wait for the dealer's reply.

:cry:

USAFCOP · **Posted:** Mon Jan 23, 2006 1:16 am

Just take her to a steep concrete hill, and then dump gear oil and your parts on the snow covered road, and then call the roadside assistance number :lol:

Seriously as Jpzkj said, They know about it and LOST, (look in the KJ sales brochure) Others have been warantied, so they better warranty yours, especially being an '04!

With how hard I wheel mine I am constantly knocking on wood!!!

DaveKJ02 · **Posted:** Mon Jan 23, 2006 1:46 am

Aluminum sucks.

pixeldzn · **Posted:** Tue Jan 24, 2006 3:24 pm

I split off the posts about the collar reinforcement to a new thread. In the process I lost some of the posts that didn't pertain to the colllar. Somehow the "split from topic" command didn't work right. Sorry some of the other comments are gone - repost if you can remember what you said previously!!!

New topic is here:
http://www.lostjeeps.com/forum/phpBB3/vie ... php?t=5187

NU ARTY BOY · **Posted:** Wed Jan 25, 2006 2:22 am

It still kills me that Jeep would use aluminum for the diff casing. Mountain bikers know very well that aluminum is lighter than steel but half as strong. So if it takes twice as much material to get the same strength....maybe that is why you don't see many aluminum frame mountain bikes in shops anymore. Its either Cro-moly or some sort of alloy material. Or Titanium if you have the money to pay for it.

ManicMechanicJoe · **Posted:** Wed Jan 25, 2006 5:44 pm

aluminum is half as strong as steel and 2/3 the weight. The real advantage of aluminum is that it dissapates heat. It can be worthwhile if used on a non-structural part of the vehicle (fenders etc.). Other then that it is worthless.

Eddo · **Joined:** Thu Jul 07, 2005 7:01 pm **Posts:** 1214

Aluminum is not bad if done correctly. Strength varies greatly depending on the alloy and the constructing process. Airplanes are made of aluminum and experience some incredible stress. I'm sure if DCX was willing to spend a few more dollars and use a better alloy we would not have any of these problems.

I have heard (through the grape vine though) that the engineers where shocked with the diff broke on the KJs at camp Jeep. They said it didn't make sense, they where designed and test to take something like 3 times more torque than the half shafts. Maybe it was a poor design and not test properly or they have quality control issue in the production of the housings.

brian · **Joined:** Sat Nov 12, 2005 10:05 am **Posts:** 19

I was told (by the dealership) lifting the liberty could increase the chances of damaging the front diff, and also the transfer case. I for one do not see how this could be a factor. Please let me know if anyone out there has had this kind of problem on a stock lib.

This should make you go "WHAT THE Crap"

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