opo wrote:
The front differential on the KJ seems to be very weak. Few members of the board have reported diff breakages. It seems that the housing is weak.
Well, I don't know about "very weak".
There are (according to the members list) 1647 members and I think there have been maybe 3 or 4 breakages reported. All of which have been in similar circumstances; the wheels have been spinning and suddenly grabbed, or the truck's been airbourne which amounts to the same spin/grab scenario. And in all cases, unless someone wants to tell me different, the case has broken around the input shaft.
So it's not "very weak" or there would be loads more breaking. One particular member of our club wheels his KJ
very hard. He's gone through a couple of transfer cases, front axles, rear axles, rear diffs and a new engine. And
his front diff casing is still intract. Presumably because he hasn't hit the exact specific set of circumstances which will cause the front casing to fail.
Assuming that the input shaft
is the weak point in the front diff it's (possibly) easy enough to reinforce with the "Eddo's Band Aid" steel collar.
As I say, if someone wants to talk about the front diff casing failing in a different way to the descriptions I've seen then I'm all ears. Maybe we can get steel reinforcments made up for any other weak points too.
But this is getting off-topic, so I'll shut up!

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