2002 SR5 4x4 Rear Diff Failure

[tgaunce]

My son has been driving this, a recently purchased 2002 SR5 4x4, Sport Edition with 117K miles. Thursday night as he was pulling out there was a loud noise and no more go. Got towed home via AAA.

If you put it in gear the driveshaft spins freely while the vehicle sits there. Rear tires are blocked to hold it from rolling.

I haven't opened it up but guessing I need to replace the diff. Any advice on what to check? Could it be something simple? There were no symptoms leading up to this except for a leaking rear axle seal that was repaired.

If I need to get a diff how do I tell the gear ratio for sure since there is no possibility of a spin test ... open it up and count? The diff housing is marked with 35140.

I've done some work before, put a locker in my Bronco and lifted it, and think I could handle swapping the diff but am still a bit unsure of the diagnosis. Am also going to get one of my buddies to look at it.

Any advice is appreciated.

Tony

 

[4-Ripcord]

sport editions have 4.10's. Find a junkyard axle and either swap axles or just swap the diffs.

 

[Nelsonmd]

My son has been driving this, a recently purchased 2002 SR5 4x4, Sport Edition with 117K miles. Thursday night as he was pulling out there was a loud noise and no more go. Got towed home via AAA.

If you put it in gear the driveshaft spins freely while the vehicle sits there. Rear tires are blocked to hold it from rolling.

I haven't opened it up but guessing I need to replace the diff. Any advice on what to check? Could it be something simple? There were no symptoms leading up to this except for a leaking rear axle seal that was repaired.

If I need to get a diff how do I tell the gear ratio for sure since there is no possibility of a spin test ... open it up and count? The diff housing is marked with 35140.

I've done some work before, put a locker in my Bronco and lifted it, and think I could handle swapping the diff but am still a bit unsure of the diagnosis. Am also going to get one of my buddies to look at it.

Any advice is appreciated.

Tony

You could put it in 4wd and do the spin test on the front wheels. It might help to completely disconnect the rear drive shaft first. You would do the test the same, just with the fronts.

Ripcord might be right, but I wouldn't risk the couple hundred bucks for a diff without actually checking.

 

[Big John]

You're going to have to pull it anyhow so why not just yank it and count? Getting the diff out is very easy.

 

[brian2sun]

It sounds like maybe you broke an axle shaft.

 

[Y2KSR5]

Wow! Ive not read about any diff failures before. That surprises me! Mine impress the hell out me. No noises at all. After driving POS Heep Grand Cherokees, every single one I had (5) had to have the diffs rebuilt....often.

 

[tgaunce]

Thanks for the responses. Did not get to this today.
Will open it up tomorrow and see what is broken.
Hoping for an axle.
More to come ...

 

[tgaunce]

So I tried to diagnose things a bit further.
Was a bit timid to pull the diff after reading the write-up on axle seal replacement.
I have to pull the axles to get the diff out and if it is the axle, how do you get out the broken segment out?
Also, I don't have any access to parts today if needed.
Is there another way to diagnose the issue, axle vs diff, without taking it all apart?
Maybe I just bite the bullet and pull it apart? Again, a little bit hesitant sice if I get some help with this I may want to move it and that'll be easier to do fully assembled.

I did lift up the front and rotate the tire to figure out gear ratio ... 20 tire revolutions == 41 drive shaft revolutions == 4.10 gears.

Advice?

Thanks
Tony

 

[Nelsonmd]

If you lift one of the rear wheels (in 2wd and N) and spin the wheel, you can see if the DS turns, repeat on other side. If only 1 wheel turns the DS, then you probably broke and axle, if neither turns the DS, then you probably stripped the gears in the diff. If both wheels turn the DS, then you don't know.

This may be a little tough because even if you stripped the diff gears, you may get some friction in there, but it might work.

 

[tgaunce]

If you lift one of the rear wheels (in 2wd and N) and spin the wheel, you can see if the DS turns, repeat on other side. If only 1 wheel turns the DS, then you probably broke and axle, if neither turns the DS, then you probably stripped the gears in the diff. If both wheels turn the DS, then you don't know.

This may be a little tough because even if you stripped the diff gears, you may get some friction in there, but it might work.

So I tried this.
Lift up driver side rear and spin the tire: The DS does not move.
Lift up the passenger side rear and spin the tire : The DS rotates.
Guess I have a busted axle on the driver side?
Any tips on getting the broken axle out?
Guess I'll call around couple salvage yards tomorrow to try and find an axle assembly. Anyone know of any good sources in the Raleigh, NC area? What is a reasonable price? Anything to look out for? Change seals I guess?

Guess I should pull the axle to be sure before buying.

Thanks Again
Tony

 

[Singtoe]

So I tried this.
Lift up driver side rear and spin the tire: The DS does not move.
Lift up the passenger side rear and spin the tire : The DS rotates.
Guess I have a busted axle on the driver side?
Any tips on getting the broken axle out?
Guess I'll call around couple salvage yards tomorrow to try and find an axle assembly. Anyone know of any good sources in the Raleigh, NC area? What is a reasonable price? Anything to look out for? Change seals I guess?

Guess I should pull the axle to be sure before buying.

Thanks Again
Tony

I have an axle half for sale. It will include the axle shaft, the hub bearing and the brakes. The only thing that you have to do is unbolt the brake line, undo the parking break clevis and unbolt 4 nuts that hold the hub to the axle and it is out.

I will let you have it for $90 dollars.

If you throw in another $100, I will come over, remove the diff, remove the broken pieces, re-install the diff, and install my axle. I will bring oil, and brake fluid to complete the job. (This is assuming that you live in Raleigh and not Durham or what not).

 

[tgaunce]

I have an axle half for sale. It will include the axle shaft, the hub bearing and the brakes. The only thing that you have to do is unbolt the brake line, undo the parking break clevis and unbolt 4 nuts that hold the hub to the axle and it is out.

I will let you have it for $90 dollars.

If you throw in another $100, I will come over, remove the diff, remove the broken pieces, re-install the diff, and install my axle. I will bring oil, and brake fluid to complete the job. (This is assuming that you live in Raleigh and not Durham or what not).

Sold ... the install too. I'm in N.Raleigh about 1/2 mile from the intersection of Six Forks and Strickland. I'll pm you my contact information.

 

[codyjh]

Check out, ECGS East Coast Gear Supply

 

[Singtoe]

Another satisfied customer.


I do need some input from the community.

The axle wasn't broken but the spider gear in the diff was cracked in half.

He is the question - what would cause this.

The truck only had 117k on it but when i went to work on the axle, it had a salvage yard axle already installed under it from the previous owner. So this will be the second time the axle or diff has gone out on this truck in less then 117K.

My theory and i need someone to back it up. The traction control warning lights were on. I think the trac system is messing up while the truck is in motion. I think it is locking up the brake and applying throttle causing the destruction that we are seeing.

To help out the the OP, How can he disable the trac sytem in his 4runner and not have the warning or check engine light come on?


BTW I hate 2002 4runners.:biggrin2:

 

[4-Ripcord]

Disable trac with no warning light.. hmm.

Only thing that comes to mind is the andymod2.0 and remove the bulb for the light from behind the gauges. But keep in mind that will also disable vsc.

Other than that. I dont know. Sounds like a tough problem.

 

[tgaunce]

Another satisfied customer.


I do need some input from the community.

The axle wasn't broken but the spider gear in the diff was cracked in half.

He is the question - what would cause this.

The truck only had 117k on it but when i went to work on the axle, it had a salvage yard axle already installed under it from the previous owner. So this will be the second time the axle or diff has gone out on this truck in less then 117K.

My theory and i need someone to back it up. The traction control warning lights were on. I think the trac system is messing up while the truck is in motion. I think it is locking up the brake and applying throttle causing the destruction that we are seeing.

To help out the the OP, How can he disable the trac sytem in his 4runner and not have the warning or check engine light come on?


BTW I hate 2002 4runners.:biggrin2:

Extremely satisfied customer. Singtoe went above and beyond!!
Swapped the drivers side rear axle and swapped spider gears from his diff to mine and all the other associated work, in my driveway!

Both the VSC and TRAC lights have been coming on since a short time after getting it a few months ago. Next thing to diagnose and fix. It is currently disabled with the relay pulled until we can sort it out.

Tony

 

[Singtoe]

Disable trac with no warning light.. hmm.

Only thing that comes to mind is the andymod2.0 and remove the bulb for the light from behind the gauges. But keep in mind that will also disable vsc.

Other than that. I dont know. Sounds like a tough problem.

I think doing that would also create a chk engine light to come on thus create an issue regarding vehicle inspections.

 

[4-Ripcord]

Does a missing bulb trigger a CEL?

 

[the great him]

Does a missing bulb trigger a CEL?

no, it sounds to me like there is some sort of electrical short in the traction control system some where causing it to engage. but that shouldnt create enough resistance to break gears... i have a feeling that the previous owner my have abused the rig and drove the piss outta it and broke the original rear end and just swapped it with another one from a wrecking yard and did the same to this one but sold it before it failed...

 

[SamSter0077]

I have an axle half for sale. It will include the axle shaft, the hub bearing and the brakes. The only thing that you have to do is unbolt the brake line, undo the parking break clevis and unbolt 4 nuts that hold the hub to the axle and it is out.

I will let you have it for $90 dollars.

If you throw in another $100, I will come over, remove the diff, remove the broken pieces, re-install the diff, and install my axle. I will bring oil, and brake fluid to complete the job. (This is assuming that you live in Raleigh and not Durham or what not).

Damn this guy is a life Saver!

Another satisfied customer.


I do need some input from the community.

The axle wasn't broken but the spider gear in the diff was cracked in half.

He is the question - what would cause this.

The truck only had 117k on it but when i went to work on the axle, it had a salvage yard axle already installed under it from the previous owner. So this will be the second time the axle or diff has gone out on this truck in less then 117K.

My theory and i need someone to back it up. The traction control warning lights were on. I think the trac system is messing up while the truck is in motion. I think it is locking up the brake and applying throttle causing the destruction that we are seeing.

To help out the the OP, How can he disable the trac sytem in his 4runner and not have the warning or check engine light come on?


BTW I hate 2002 4runners.:biggrin2:

uh... Burnouts?