Jeep JK Differential Fail BOOM!

When rebuilding differentials, you will come across some diffs that have had a massive failure. This one is no exception!
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Last updated: May 11, 2023

[@theomegawerty9688]

Same thing happened to my dana super44. Repairing it was quite the adventure....

[@larryfischer364]

I've seen 12 bolt and 9 pinion snaped off right behind the yoke ,but this is the first time Ive seen a bent pinion

[@davestewart9146]

All I can say is wow what a mess, thanks for the video 👍😁

[@johnbayne9200]

Good luck Mike, looking forward to seeing the KZbin of the repair on this diff. Nice job diagnosing and documenting the issues.

[@TheBFHGarage]

Not going to be one. I already have a good JK Rubicon re-gear video and I just don't have the time today! Sorry, but stay tuned for more!

[@510dan1]

That had to be making noise for A Long Time.

[@charlesb4267]

I came down here to make a similar comment, surely there had to have been some noise coming from that diff before its final death spiral. The tires don't look that aggressive as I could see really noisy tires covering up a diff noise issue.

[@charlesb4267]

Although slightly different, I remember years back a neighbour had his rear end lock up on him just down the road from our farm, 1/2 ton gm pickup. What he initially saw was the three piece drive shaft having failed as per one of the ujoints I believe and possibly one portion of the shaft. However that was just visible upstream carnage from what really happened and with such a scenario I am sure its possible to sustain transfer case and transmission damage and even into the engine perhaps. So what really started the chain of events was that little special bolt that holds the cross pin into the carrier that holds the carrier spiders. That bolt ether broke its tip off or backed out and then the through/cross pin came sliding out one side of the carrier and came around slamming down on top of the pinion, boy does that ever stop a diff in its tracks !. So that makes me wonder with the bent pinion shaft, what if anything upstream in the drive line took more of a shock load then it could handle. What say your thoughts Mr BFH ?

[@TheBFHGarage]

There's always that chance. When I removed the driveshaft I checked the t case and it was very smooth. What locked this one up was a broken tooth got wedged in between the pinion and ring gear. That'll lock you up instantly unless something blows up 😂

[@charlesb4267]

@@TheBFHGarage Yes, and all depends how much rpm and how deep into the little pedal on the right was being deployed at the time of gear "impact". Of course there isn't a thing you can do about any possible hidden damage elsewhere, it will certainly show itself if there was any though at some point. One thing is certain though, you will never run out of vehicles to repair ... only time to repair them all !

[@user-pu2ht5lw3g]

Great videos! Very educational. Any tips on how to hold the ring gear still to torque the ring gear bolts? I'm re-gearing a 2016 JKU with an Eaton limited slip. Thanks

[@TheBFHGarage]

If you didn't have a big enough vise, then a shop press works. Use a 2x4 on the bottom.

[@user-pu2ht5lw3g]

@@TheBFHGarage man that suggestion worked like a charm. I used the press method and got it torqued, now moving on to the pinion. Thanks again!

[@richardmiller3808]

Yep, it’s always good to change those diff fluids about every 30,000 miles even less miles if you’re going to go out and do stupid stuff like me lol

[@ke6bnl]

Must of had diff grease all over the floor

[@timoconnor9676]

Don’t you wish you were 5’6”

[@TheBFHGarage]

😂🤣

[@MrStaybrown]

Lol. People always say, "I wish I was tall." My response as a tall man is, "No, you don't." 🤣

[@Coolhansolo]

Someone didn't change their oil and had a leak cooked the differential good. That's gotta cost alot !! Wow wonder what the engine looks like probably sludge city. Yikes 😂

[@charlesb4267]

Yes, I think the whole Jeep possibly needs some attention, draining and inspecting the front diff oil, the transfer case and whatever course of action with the automatic trans ( pan drop and filter change ), and yes the engine too. Having said that I have seen myself where the engine oil is changed often ... all is good there but the rest of the drive line oils are sadly neglected.

[@Coolhansolo]

@charlesb4267 Those engines and transmissions aren't know to be all that. Neglect means they are probably on the way out too.

[@charlesb4267]

@@Coolhansolo But I thought all manufactures claim to be THEE BEST. And speaking of servicing, I get the distinct idea that these engine oil monitors or how some are designed are causing numerous vehicle owners to have a false sense of assuming the engine oil is good because the dash tells me so, and some run the oil far too long and the engines premature life tells the story in the end.