Hi folks,

Background:
Got an air activated Locker in the back of my JK Sport D44 (was originally open diff) and a big red diff cover made in australia with a dipstick on it. Running factory oil level of 2.2L with no obvious dramas.

Except for one.

Constantly having pinion problems.

First pinion died (became very loud) no more than 3000km from fitment of the Locker, so the place which fitted it replaced all the bearings again.

Second pinion has been going OK except it is now about to be onto its second replacement seal (diff has now done almost 20,000km). Diff itself is definitely louder than it was when it was brand new and unlocked. Makes just a constant noise that I can't really describe. Just sounds like a Dana that has done 200,000km if that makes any sense. Have changed oil, using a synthetic GL4 75w90.

After a good 2 hrs driving the oil level on the dipstick is about 20mm which indicates the crown wheel is most likely getting enough oil on it to flick up into the gallery for the pinion lubrication.

Noticing even with fresh oil in it there's alot of metal in the oil. When I did the oil change the magnets had collected alot of fine metal paste which was a bit concerning but not unexpected, the magnets on the drain plug of the diff cover are far more powerful than the standard magnet which had collected very little residue.

Have heard of someone else in Aus ordering a replacing diff housing as theirs was faulty (pinion problems as well) but I'm failing to see how it could be a problem when everything works otherwise so guess I'm turning to a larger market to see if anyone else has been through something similar.

My personal feeling is that the pinion hasn't been shimmed properly? (not really familiar with the danas, but i think they're like the toyotas with a crush shim on the pinion?)

Thanks in advance i guess.

Tom

 

The shop doing the install has clearly no idea what they are doing. Take it to another and have the original shop pay for the repair by someone that can actually do it. They have either not appropriately crushed the crush sleeve resulting in improper pinion preload and seating of the bearings or they have left something out like perhaps the oil slinger. Either way, this should not be occuring and it should be repaired promptly and on their dime.

 

thanks for your thoughts guys.

won't be me doing it, will be the shop which fitted the lockers getting it back to the way it is meant to be. Bloody pack of turkeys