Front differential discussion

[Gene Dios]

It seems a lot of failures are at the inner housing and there's a video example of the shaft itself breaking. Has anyone seen one break at the outer housing?

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[Jim@WILDHORSES]

Just to add to the conversation I severely injured a driver side CV (outer M210 FDU) and somewhere around the same time broke the intermediate shaft. There are a few hard spots at Prison Hill OHV Carson City. Hope to see some of you there in Oct. for Bronco Driver Super Cel.
https://www.broncodriver.com/index.php/nevada-event/
Anyway, pulled and opened the FDU, split the case, smacked the broken piece of the shaft out. Time to get this back together. I can't find torque specs for the 12 case bolts. I have searched the web high and low. By the time someone post the specs I will have this back together but maybe it will help the next guy or gal. Happy wrenching!

Jim

 

[Snacktime]

Just to add to the conversation I severely injured a driver side CV (outer M210 FDU) and somewhere around the same time broke the intermediate shaft. There are a few hard spots at Prison Hill OHV Carson City. Hope to see some of you there in Oct. for Bronco Driver Super Cel.
https://www.broncodriver.com/index.php/nevada-event/
Anyway, pulled and opened the FDU, split the case, smacked the broken piece of the shaft out. Time to get this back together. I can't find torque specs for the 12 case bolts. I have searched the web high and low. By the time someone post the specs I will have this back together but maybe it will help the next guy or gal. Happy wrenching!

Jim

Well that is good news since you didn't take the ring gear out. Look like the failure is at the edge of the carrier.

Oh we use the same rescue service @SS Bronco

 

[Aonarch]

Just to add to the conversation I severely injured a driver side CV (outer M210 FDU) and somewhere around the same time broke the intermediate shaft. There are a few hard spots at Prison Hill OHV Carson City. Hope to see some of you there in Oct. for Bronco Driver Super Cel.
https://www.broncodriver.com/index.php/nevada-event/
Anyway, pulled and opened the FDU, split the case, smacked the broken piece of the shaft out. Time to get this back together. I can't find torque specs for the 12 case bolts. I have searched the web high and low. By the time someone post the specs I will have this back together but maybe it will help the next guy or gal. Happy wrenching!

Jim

https://www.fastenermart.com/files/metric_tighten_torques.pdf
^ A lot more options

 

[mattusmc]

It seems a lot of failures are at the inner housing and there's a video example of the shaft itself breaking. Has anyone seen one break at the outer housing?

this actually just happened this weekend on my driver side axle

 

[Snacktime]

this actually just happened this weekend on my driver side axle

That is the inner axle failure I have seen. Get a couple more pictures of the failure, kind of looks like a pocket in the casting.

 

[mpeugeot]

That is the inner axle failure I have seen. Get a couple more pictures of the failure, kind of looks like a pocket in the casting.

Axles should never be cast, they should be forged. If they are cast, they will fail as a general rule.

 

[Snacktime]

Axles should never be cast, they should be forged. If they are cast, they will fail as a general rule.

My bad, still looks like a pocket. Maybe a bad ingot got forged as I wouldn't be surprised by a metallurgic defect. Back to my

 

[mattusmc]

That is the inner axle failure I have seen. Get a couple more pictures of the failure, kind of looks like a pocket in the casting.

the luckiest place to snap honestly, no damage to the diff

 

[popo_patty]

Well that is good news since you didn't take the ring gear out. Look like the failure is at the edge of the carrier.

Oh we use the same rescue service @SS Bronco

@SS Bronco recovery service

 

[Quest]

Just had my FD go this past weekend. I thought it was the driver-side CV, but they told me both CVs looked okay. Of course, the part is on backorder, so we will see how long until I get it back. Trying to turn around on a bad mud hill after finding two downed trees in the way. Recovery boards out, and then just a loud crack sound with a harsh shift out of reverse to put it into park.

 

[Snacktime]

Just had my FD go this past weekend. I thought it was the driver-side CV, but they told me both CVs looked okay. Of course, the part is on backorder, so we will see how long until I get it back. Trying to turn around on a bad mud hill after finding two downed trees in the way. Recovery boards out, and then just a loud crack sound with a harsh shift out of reverse to put it into park.

You have a front locker? M190 or M210?

 

[Quest]

You have a front locker? M190 or M210?

I'm not certain the version, but I do not have the front locker. 2023 4Dr BD 2.7

 

[Snacktime]

@Quest M190 front differential if you don't have a locker. Let us know if they take it apart and tell you exactly what failed? Could be the part time unit or the actual differential.

 

[Strizzo]

So the m210 drive CV is 1" longer than m190. It fits but is just to long and the seal will not seal.

The other issue is there is no bearing supporting the drivers CV. The CV is metal on metal through the carrier to the spider gears. Look closely you can see the bearing is supporting the carrier. I thought the bearing was seized initially.

Here you can see gouging on the shaft from rubbing on the carrier. It took me 3 hours with a slide hammer to get this pos out.

Very disappointed in the design. A simple roller bearing would easily prevent the damage. This is going to be a issue with both the m190 and m210. We need to find a bearing that fits inside to eliminate the play that can be pressed in behind the seal. This should also help with keeping the seal alive since I had to change both sides here at 5k miles.

Seems like it would be possible to machine out some area and press in a bronze bushing for additional support. I know that with the 2nd gen tacomas, they deal with a vibration after lifting by replacing the outer bearing with a bushing. not exactly the same situation but could be looked into. It looks like where that metal transfer is on your cv is at the differential bearing. almost like the wrong size inner race is in it causing the cv to wobble inside the bearing and rub inside the race.

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