Rear diff exploded...kinda.

[owyheerat]

This bolt should be screwed to something inside.

top view

and it shouldn't have this big pimple

ECGS complete 3rd member with 529's and ARB 132 installed 2/16. It has worked great, no problems at all. I have 15k miles on it.

I was driving to the trail head (in 2wd), doing 65 when I heard a really loud bang (like a gun shot). It scared the piss out of me, and I asked my adult son what that was and he convincingly said that it was a rock. We argued about that for a few miles.... Got to the trail head to air down, mainly for washboard, this is not a technical trail. I looked my rig over and didn't see any damage or leaks, so we proceeded to run the trail. I only had put it in 4wd twice, I did lock the rear on one of those occasions, due to soft, loose soil. The truck made no unusual noises, nor did I perceive any difference in drive ability.
I then drove it home (110 miles) the next day without noticing anything wrong. In fact I put the truck in neutral on 2 occasions and coasted at 70 mph.
I didn't notice the damage until I pulled it into the garage and saw a small spot of oil under the rear diff. This caught my eye right away, because I have no leaks at all.

Anyone have any ideas where the bolt belongs? And what may have caused this?

Full disclosure: I called ECGS 1st thing this morning and told them about the incident and sent them some pics. I am waiting to hear back from their experts.

Durwin

 

[nevada]

I expect to see some damage. that looks like a ring gear bolt.
not properly torqued, or without locks or Loctite. or a combination of the 3.

 

[rkntoy]

Ring gear bolt

 

[JZiggy]

Is there where the air line goes into the diff? Seems like it should be on the 3rd member itself and not on the axle housing. I don't have ARBs, not very familiar with how they're set up.

Edit -- now that I study it more I see that a bolt has been shoved from the inside out of the axle housing. Ouch!! Ring bolt would make a lot of sense in this case... guess the Loctite was forgotten

Have you drained the fluid to see if you have any chunks in there?

 

[owyheerat]

I expect to see some damage. that looks like a ring gear bolt.
not properly torqued, or without locks or Loctite. or a combination of the 3.

Ring gear bolt

Damn you guys are good. I'm hoping ECGS takes care of me, since they built the complete 3rd member.

Is there where the air line goes into the diff? Seems like it should be on the 3rd member itself and not on the axle housing. I don't have ARBs, not very familiar with how they're set up.

Edit -- now that I study it more I see that a bolt has been shoved from the inside out of the axle housing. Ouch!! Ring bolt would make a lot of sense in this case... guess the Loctite was forgotten

Have you drained the fluid to see if you have any chunks in there?

Yes, I drained it last night. Found a small amount of metal 'dust' and 1 small (like an eye lash) pc of metal.

 

[octanejunkie]

If that is a ring gear bolt protruding through the housing, and if ECGS did the gear install on the 3rd, then they owe you some serious make good

And if that is a ring gear bolt, you are super lucky it went outboard and got stuck vs ricocheted inwards, possibly lodging in the gear set or locker mechanism causing your entire rear diff to grenade on the fwy at speed causing lord knows what kind of incident

You sir, are lucky af

 

[JZiggy]

See if they can show you pictures of the ring gear being installed with Loctite. That's how Zuk does it. Pic from my rear diff being set up, courtesy of Zuk:

 

[owyheerat]

If that is a ring gear bolt protruding through the housing, and if ECGS did the gear install on the 3rd, then they owe you some serious make good

And if that is a ring gear bolt, you are super lucky it went outboard and got stuck vs ricocheted inwards, possibly lodging in the gear set or locker mechanism causing your entire rear diff to grenade on the fwy at speed causing lord knows what kind of incident

You sir, are lucky af

Yes, its a complete 3rd member built by ECGS. I'm confident they will make it right.

Yeah, when I looked under there and saw that bolt sticking thru, I thought, wow that could have been real bad! I thank the Lord for guardian angels...

 

[owyheerat]

See if they can show you pictures of the ring gear being installed with Loctite. That's how Zuk does it. Pic from my rear diff being set up, courtesy of Zuk:

Will do.

Thanks

 

[owyheerat]

I just got off the phone with Seth at ECGS, they are gonna take care of me. You guys were indeed right (@nevada [MENTION=135317]rkntoy[/MENTION]), it is a ring gear bolt.

They want me to send the entire axle assembly to them so that they can weld a new Barney's HD diff cover Toyota Pick Up Heavy Duty Differential Cover and repair all damage inside. They are paying the freight both ways. I couldn't ask anymore from them. What a great company!

This is exactly why I chose to spend my hard earned dollars with them.
[MENTION=51127]Dous[/MENTION] Big shout out to East Coast Gear Supply for standing behind there product and providing great customer service.

Durwin

 

[rkntoy]

I just got off the phone with Seth at ECGS, they are gonna take care of me. You guys were indeed right (@nevada [MENTION=135317]rkntoy[/MENTION]), it is a ring gear bolt.

They want me to send the entire axle assembly to them so that they can weld a new Barney's HD diff cover Toyota Pick Up Heavy Duty Differential Cover and repair all damage inside. They are paying the freight both ways. I couldn't ask anymore from them. What a great company!

This is exactly why I chose to spend my hard earned dollars with them.

[MENTION=51127]Dous[/MENTION] Big shout out to East Coast Gear Supply for standing behind there product and providing great customer service.

Durwin

They are a great company from what I have seen. They spent a lot of time with me on the phone about my front diff oil leak - and I had not even bought anything from them.

 

[nevada]

I just got off the phone with Seth at ECGS, they are gonna take care of me. You guys were indeed right (@nevada @rkntoy), it is a ring gear bolt.

They want me to send the entire axle assembly to them so that they can weld a new Barney's HD diff cover Toyota Pick Up Heavy Duty Differential Cover and repair all damage inside. They are paying the freight both ways. I couldn't ask anymore from them. What a great company!

This is exactly why I chose to spend my hard earned dollars with them.

@Dous Big shout out to East Coast Gear Supply for standing behind there product and providing great customer service.

Durwin

wow. that's impressive. this right here will likely get them more business. it will more than make up for the repair/shipping costs. stand up company.

 

[Scramble]

Wow, that's amazing, could have been so much worse. Great customer service by ECGS!

 

[thegipper]

You seriously dodged a bullet. And kudos to ECGS for being an outstanding company and standing by their work.

 

[AssBurns]

ECGS by far has the best customer service I have ever dealt with. I dealt with them a few times and always have good things to say. Their warranty is outstanding and they are quick and easy to deal with. And they always answer the phone during business hours which is a huge bonus