So my gears were upgraded to 5.13s from 4.10s last week... Got a d44 in the rear and I never touched the actual diff housing... other that when I installed the ring gear. So last night i was driving about 30 mph my jeep came to an abrupt hault and a loud bang! Towed it to my hobby shop on base and cracked it open to discover that the spider gears inside the differential were in pieces... The spline (I think thats what its called) that runs in the middle of the housing sheared and actually cracked the entire housing... in return my new yukon ring, pinion, and differential is destroyed.. Horrible pics to follow.. So what caused this? Baclash was set, mesh patterns were on point.... Im confused. BTW atleast ten jeeps (4 or 5 jk's) drove past me and didnt even offer a single hand to push me out of the intersection.... assholes!

 

I'm gonna go with installer error...

I know, I know, just had to say it.

There was a similar thread not too long ago. I don't recall the responses/feedback that was given, so I'll see if i can track it down. (he backed out of his garage with the intention of turning it around to get the other end in to replace those gears, and as soon as he turned he heard the snap/crackle/pop. or something very similar to that.)

 

hate to say it, but its a risk you take when trying to do your own gear install. hope you get it squared away and back on the road soon!

 

Ok, I reviewed your post several times and I see what you are referring to. The housing u describe is the carrier (correct?). With everything in pieces it will be hard to determine what initially failed. Perhaps a bolt came loose or a some pinion/ring gear teeth broke, got caught up in the gears, and boom.

I am one who also took on the task of performing my own gear swap/ locker install. I was very nervous the first 500 miles after. My front pinion came loose after about 4000 miles. I believe it was because we didn't properly/fully seat the pinon bearing races. Although we THOUGHT we did. They were definitely a bitch to get in. I am lucky it was the front, and I repaired it quickly. When I took on the task, axle failure was a risk I was willing to accept. Over 20k miles and I haven't had a failure.

It may be difficult to determine root cause. Since it was fine before the install, common sense will lead most of us to believe an incorrect install.

Good luck. I hope u get it taken care of.

 

Looks like a pinion tooth sheared of and destroyed everything... Do you think Yukon will replace under warranty?

 

This is why I refuse to do anything on the gears myself. I like the security I have that at worst case, if someone else did it, I have full warranty. Good luck finding what happened and getting back on the road. No one needs these issues in life.

 

Sorry to hear about this. Hope youre able to sort through what happened and get it fixed. Also cant believe so many folks drove right on past you, that blows.
I contemplated for a long time on whether or not to do my regearing myself or pay to have seomone else take on the risk and warranty their work. I went for the latter. so far no issues. money well spent.

 

Could you post a few pics when you get a chance? I would like to see the damage, and maybe some cause/effect analysis from a few of the forum gearheads. It may help those of us that want to tackle a re-gear in the future.

And I am sure that whoever you bought from would like to see some pics as well.

 

how was carrier and pinion bearing preload? Set properly?

 

ummmm yaaaa good luck with that.....BUT can't hurt to call..