So I'm supposed to be going home this weekend, I'm supposed to be on the road in 30 minutes... I don't think I can go anywhere. Well let's just say I'm afraid to. A few days ago, I started noticing a thump coming from what felt like the rear, but I couldn't duplicate it. Then as I was driving home today, I noticed a pound type feeling actually come through my hurst shifter arm.

Got home and did a full inspection of the trans, transfer-case and driveline, visually. Everything checked out perfect.

I get to the rear end, and noticing there's fluid on the cover more so than normal, I start inspecting it. This is what I find:









I have a 120mi trip home and i'm deathly afraid right now my Torsen is going to blow up, taking out the ring gear, if it isn't already gone, as well as the splines on the shafts... PLEASE help me guys... I need to know what to do. I have limited tools, or at least the onces I carry in the toolbox, and I have access to an auto-parts store... I just need to know what to do... I'm afraid of taking the diff cover off.

 

It doesnt look like you have a choice but to open it up and see what the hell happened in there. Definitely dont get on the highway without knowing its safe.

 

pull the cover off, RTV silicone will seal it back up, look for large pieces of gear, down to small gravel or coarse sand... if none of this is found, change the fluid, may aswell not put the crap back in...

that diff cover HAS to come off either way... you may be lucky, it might have been something small that created those dents, and as long as you get it out of there, it won't munch the rest of the gears while driving... and you might be fine...

 

your bearing retainer may have come loose

looks like your gonna have to pull the cover off

 

Uploading new pics with cover off... I believe it's a bolt that's part of the Torsen itself that sheared off... Dunno how though.... Hang on

 

what year truck did you pull the axle from?
Because it looks and sounds like the torsen exploded. I really hope I'm wrong. Good luck.

 

Look down in the bottom.. You see a bolt head. This is what I think SMACKED the cover, as the ring gear bolts spun around it picked it up occassionally, which is why I couldn't replicate the "boom".... Some scuffs on the ring gear bolt heads, some scuffs on the gear on the outside, but nothing looks horrible or un-drivable. Did notice some metal chunks, but as you look at the bolt head that sheared off, you can see why. I don't think i'm as screwed as I thought. There's supposed to be 4 bolts holding the Torsen together, or so Shane tells me. Will I be ok with just running on the 3 and taking the driving light and easy? I haven't done anything to the truck in 4-5 weeks, and this is what happens! KARMA! lol







You can see the hole where the bolt was sheared out of.... Kinda odd...



Pinion gear is safe!



Bolt head that sheared out...





What's the verdict?

 

I'm thinkin slap a new bolt in there(easier said then done of course) and you should be ok.

 

It was pulled from an early 02 Level 2.... Shane knows more about it than me, I just pulled it and installed it in my truck haha

 

if you have to go somewhere, fill it back up with fluid. and drop the rear drive shaft. front wheel drive...

 

I would clean it out, replace the cover, fill 'er up, and drive home. That's just what I would do though. I don't see anything else happening on the way home, just make sure the rest of the bolts in there is good and tight.

 

LoL hopefully you have better luck with an 02 torsen then me

judging by the pics you uploaded you have so far

 

yeah he should be fine going home but I'd get that bolt replaced before too long, just in case.

 

I'd go ahead and take the bearing caps off and replace the bolt. Otherwise, you'll just have to pull the cover off again.

 

I agree.

 

Is it just a ring gear bolt that sheared?
Rotate the ring gear around and see where it came from and what is left. You might be able to drill it out and put a new one in with it in there. Or if the threads are there you may be able to clean the shavings out, fill it up and get home.

 

x2

Still sucks though.

 

Um... I would, maybe... But I currently have no front drive shaft lol

Yeah, I think that's what I'm gonna do. RTV with some new fluid, some cheaper stuff and pull it again when I have more time.

I'll upload another pic, where the bolt sheared out from.

Once I get some more free time, I'll tear into it, as long as I have Shane or Austy to help me pull the carrier out and get that bolt drilled out so I can get a new one in there.

It's not hard, takes 5 mins... I'm just glad the bolt head didn't move to the other side of the ring gear and really f*ck **** up.... REALLY LUCKY...

I'll upload a pic of where the bolt head came from... It's one of the 4 bolts holding the actual Torsen together... I think I'll be ok with just light driving while I'm here at school... No wheelin for me, not that I actually do much anyways, this just ensures I won't haha.

 

Yeah, you are lucky. Wonder what caused it to shear off?

 

Missing bolt head location...

 

i wouldnt make the drive man... really. thats a lil risky at freeway speed.... c clips go and your sliding on the diff at 70. if you need i can give you a hand man

 

Were you able to get the rest of the threaded bolt out that head sheared off? Or, where is it? Idk man if i'd do the drive, if that thing came out it might not be good...

 

That sucks! Looks like the entire bolt made it's way out based on one of the pictures on page 1.
Is the case cracked or is it just an illusion?

 

Where are you seeing a crack? I'll try to check it out before it gets dark and take a pic.

 

I think it is just the shape of the case. Last picture, where the bolt head sits on the carrier or ring gear, whatever it is. Looks the same on the other bolt, probably just looks weird to me.