Whoa!! It's a solid axle now... (Help me!)

[MCummings]

Okay,, If any of yall have been following my posts with this truck,, You probably all ready know where I am coming from.
And for the Other guys... Here's a quick run-down.

Truck has had nearly Zero Maintainance (spelling?).
A few of the "Must Do" things have been done,(Oil and filter, Fuel Filter,Air Filter,and front brakes) but really,, nothing has been touched on this truck.

Then,, *I* Inherited this 100K+ truck, although the odometer says, 75K it is really much higher thanks to a Rear-Wheel Speed sensor.

Okay,, here's my Problem.

I was driving to my work, and I had to do about Five 90 degree turns, all turns were with nearly full steering lock (I always back off about 1/8th-1/4th a turn) When I was doing this I heard a rather loud "POP" and it felt like I ran over a 3"round rock.
Well,, When I left, after I finished my job,, I Had to do Three more 90 degree turns, and I did these turns at a slow speed.
I noticed the rear-end would slightly "pop" and would stop the driveshaft for just a split second(with the clutch in).

After I did the series of popping corners, the truck popped two or three more times while going perfectly straight.
AFTER THAT, The rear-end was completely locked together, one whell would NOT Spin at a different speed than the other. (Me and a few friends could hear the tires "scratching")

On the way home,, with my "new Locked rear-end" the ABS and BRAKE Lights came on.
I know this has to fit in somewhere with the "popping" noises. (maybe a dirty RWSS?)


OH, AND BTW,,,!! This truck pulled a 30,000 pound trailer (not a GVWR, but actuall weight). Untill I became owner of the truck.
Well, The rear-end fluid has NEVER Been changed, and I am not sure if it has EVER been checked, or if it was checked, when the last time it happened.
I have to drive it tomorrow,, but what I think has happened, is,, the "clutches" and "plates" have disintegrated, and have locked the rear-end into one solid Axle.

Tell me your opinions, or tests I can do to see what would be the real reason for my problem here.

I know for Now, I am driving on borrowed time, and If I continue driving, I could end up with alot more things wrong,, other than just a deferential. (e. g. Bearings, axle shafts,, etc)

ANybody else experianced this?

I apoligize for the long post. I tried to get it all in here.

MerrickNJr

All opinions are welcomed. #ad


------------------
1998. 5 Dodge 3500, 2wd
5-Speed, Light Driftwood
STRAIGHT PIPED!
3. 55_LSD
A. R. E. Camper w/side pop up windows
Michelin LTX A/T 245/75/16's
Autometer Gaugeworks 3 Gauge A-Pillar Pod
Fuel Pressure (0-15Lbs)
Boost Pressure (0-35Lbs)
EGT Gauge (0-1600*F)
ATS Manifold too!!
My"REAL" Hobby

 

[dieselburner]

Originally posted by BOMBER_101:
Okay,, If any of yall have been following my posts with this truck,, You probably all ready know where I am coming from.
And for the Other guys... Here's a quick run-down.

Truck has had nearly Zero Maintainance (spelling?).
A few of the "Must Do" things have been done,(Oil and filter, Fuel Filter,Air Filter,and front brakes) but really,, nothing has been touched on this truck.

Then,, *I* Inherited this 100K+ truck, although the odometer says, 75K it is really much higher thanks to a Rear-Wheel Speed sensor.

Okay,, here's my Problem.

I was driving to my work, and I had to do about Five 90 degree turns, all turns were with nearly full steering lock (I always back off about 1/8th-1/4th a turn) When I was doing this I heard a rather loud "POP" and it felt like I ran over a 3"round rock.
Well,, When I left, after I finished my job,, I Had to do Three more 90 degree turns, and I did these turns at a slow speed.
I noticed the rear-end would slightly "pop" and would stop the driveshaft for just a split second(with the clutch in).

After I did the series of popping corners, the truck popped two or three more times while going perfectly straight.
AFTER THAT, The rear-end was completely locked together, one whell would NOT Spin at a different speed than the other. (Me and a few friends could hear the tires "scratching")

On the way home,, with my "new Locked rear-end" the ABS and BRAKE Lights came on.
I know this has to fit in somewhere with the "popping" noises. (maybe a dirty RWSS?)


OH, AND BTW,,,!! This truck pulled a 30,000 pound trailer (not a GVWR, but actuall weight). Untill I became owner of the truck.
Well, The rear-end fluid has NEVER Been changed, and I am not sure if it has EVER been checked, or if it was checked, when the last time it happened.
I have to drive it tomorrow,, but what I think has happened, is,, the "clutches" and "plates" have disintegrated, and have locked the rear-end into one solid Axle.

Tell me your opinions, or tests I can do to see what would be the real reason for my problem here.

I know for Now, I am driving on borrowed time, and If I continue driving, I could end up with alot more things wrong,, other than just a deferential. (e. g. Bearings, axle shafts,, etc)

ANybody else experianced this?

I apoligize for the long post. I tried to get it all in here.

MerrickNJr

All opinions are welcomed. #ad

I would guess from what your symptoms are that your problem is with the spider gears. I am not real familiar with the Dodge axels (yet) but I used to race Fords and that is what my 9 inchers would do when I wasted a set of spider gears.
Steve

------------------
1998 2500 Quad Cab, 12V, 5spd, 4x4, HD Transfer Case, 370HP Diamond B Injectors, #4 TST, 16cm2 Housing, AFC Spring Kit, BD Governor Spring Kit and other governor modifications, Walker Muffler, 285/75-16 BFG AT's, Stainless Steel Tube Steps, Reese Fifth Wheel Hitch, Leather, CD, LSD Dana 80 Rear, 60 Front, McLeod Dual Disc Clutch, Rancho RS9000 Shocks, Rancho Steering Stabilizer, ATS Exhaust Manifold, Psychotty Air Induction, BD Exhaust Brake, Enterprise Engine Delivery Valves

 

[dmurdock]

Don't drive it until you pull the cover and check. I had a 12 bolt grenade on me in a blazer while I was doing about 15 mph... First thing that ran through my mind was that some idiot had planted a land mine in the street (luckily it just snapped the u-joint and didn't bend the driveshaft). One new ring/pinion/carrier set later I was up and running. I would hate to think what this would be like at any higher speed (say 30-40 mph).

 

[MCummings]

Wow,, I didn't know it was that serious.

If I would have known,, I wouldn't have been doing 65MPH on the way home.

I guess I'll have to pull the cover and check.

I know *I* Am not fit or knowledgable enough to do any type of rear-end work. I really hate to see a Big 'ol repair bill, when I had my eyes shifting between a PE Comp and a MAD ECM.
MerrickNJr

 

[dieselburner]

Originally posted by BOMBER_101:
Wow,, I didn't know it was that serious.

If I would have known,, I wouldn't have been doing 65MPH on the way home.

I guess I'll have to pull the cover and check.

I know *I* Am not fit or knowledgable enough to do any type of rear-end work. I really hate to see a Big 'ol repair bill, when I had my eyes shifting between a PE Comp and a MAD ECM.
MerrickNJr

Yeah, you need to park it until you know whats going on. I transplanted a 400 inch GTO Judge engine into my Trans Am and built it up with speed parts and nitrous. It scattered the rear end so hard that both axle shafts let go and left the car. Very exciting but not recommended. #ad


------------------
1998 2500 Quad Cab, 12V, 5spd, 4x4, HD Transfer Case, 370HP Diamond B Injectors, #4 TST, 16cm2 Housing, AFC Spring Kit, BD Governor Spring Kit and other governor modifications, Walker Muffler, 285/75-16 BFG AT's, Stainless Steel Tube Steps, Reese Fifth Wheel Hitch, Leather, CD, LSD Dana 80 Rear, 60 Front, McLeod Dual Disc Clutch, Rancho RS9000 Shocks, Rancho Steering Stabilizer, ATS Exhaust Manifold, Psychotty Air Induction, BD Exhaust Brake, Enterprise Engine Delivery Valves

 

[MidwestMotorman]

Definitely do not drive the truck. Do you hear a pinging sound when driving on the highway? I had a 78 powerwagon that did the same thing with a pinging noise going down the highway. Sounded like someone tapping the rear driveshaft. I found out what it was a few weeks later when I heard a big pop (at 40mph) and stopped moving. The cross shaft that held the spider gears was running around loose (had hogged out the carrier due to age and lack of lube), hit the pinion gear, locked tight, shattered the yoke at the back of the transfer case, and left me crawling home in 4 HI after chaining the driveshaft to the frame.
I ended up changed the front and rear ends due to this problem. Not a good situation for anyone.

------------------
99 2500 QC longbox, SLT, 4x4, 24V Cummins, 5 spd, 3. 55 LSD

 

[MCummings]

When I took the truck to the dealer, I heard the rear-end kinda, squeeling/grinding it sounded like it was dry. (only above 30MPH)

When I turned the corner into the dealer, it popped a few times again,, then locked "straight axle" style.



Well the dealer called earlier and said,,



$2,400 for the Case+Labor+Tax



then he said $1,400 for case+Labor+Tax



He said the rear-end parts are unrecogignizable, and the differential is trashed. So were the "spider" gears.



Well, he gave me two totals of cost,, one if he had to replace the pinion gear, and one where he wouldn't have too.



I think the Pinion seal is shot, because I crwled under there, and the front of yoke is Covered with a thick (as in THICK, maybe . 5") coat of dirt and grease.



Well,,,

$2K for case

and

$2,563 with case and pinion.

Those are finished numbers, nothing else to add.



I think this is a BIT unreasonable, and would like to get just some new seals, a new Ring and pinion, and a "locker". I feel this would be cheaper that 2. 5 Thousand dollars.



ANythoughts, or ideas to pickup some good,, new or nearly new hardware?



Thoughts on how I should go about my decisions here. . as in. . What would YOU Do if you were here in my shoes??





Thanks in advance.



MerrickNJr

 

[Jetson]

JUNKYARD! Then you could also add a locker if you want. You could have it installed and still come out ahead.

 

[FastRam]

Bomber 101,

If it helps, I have a Dana 80 center assembly
that was removed from my truck when I put a posi unit in its place. It had 14000 miles on it when it was removed. You can have it for free if you pay for the shipping.

Glenn

------------------
96, 2500, 4X4, 5spd, SLuT, Moss green, Cab lights, factory tow hooks, Limited slip added , BD Exhaust brake with 60 psi springs, Isspro gauges. And no power mods, yet! NRA member.

 

[MCummings]

Originally posted by FastRam:
Bomber 101,

If it helps, I have a Dana 80 center assembly
that was removed from my truck when I put a posi unit in its place. It had 14000 miles on it when it was removed. You can have it for free if you pay for the shipping.

Glenn

Cool.

I took the cover off today,, and this is what I found.

Only One "spider" gear had exploded. The gear was in about 3-4 pieces,, 3 pieces were in the bottom of the case, and one piece is stuck, and is STILL Stuck in one of the openings where all the other spider gears are.

Overall the rear-end is in VERY Good shape.
There is very little overall wear.
And only a few nicks in the ring and pinion.
The "Ring" has about a nick or so,, both less than a 1/16th inch.
The Pinion didn't fair as well, but is in good shape, Very little wear, and has one nick that is between a 1/8th and 1/4 inch big.

I am not thinking of replacing the ring and pinion, unless I can Find a much faster ratio,, say a 2. 73 or even faster, or if there is one for pretty darn cheap.


Glenn!!

I am very glad for your offer.
This is a GodSend.
I would be pleased to take you up on this.
Seeing that that part seems to be the only damaged part.

Check your mail.

MerrickNJr

 

[EricBu12]

Bomber 101,
When your wallet is finally a waft of dust #ad
go and get a MAG-HYTEC diff cover. it has a drain plug and a dipstick to make changing and checking easy. also doubles the capacity to 8 qts to help keep it cool and double the life.
#ad


------------------
2001 QC 2500 4x4 bronze W/two tone Driftwood, 24valve HO 6sp. Blue chip 4-wire box, mag hytec dif. cover, BD stage 1 injectors. Westin side bars, fender flares, Rancho RSX off-road shocks, Spray on bedliner, sweet tooth grill, Leer shell Painted to match with LED marker lights, Bf Goodrich AT Tires. Bed rug inside shell W/aux marine deep cycle batt for lights, etc. M Brolins' CB mount.
Name of rig is "big bronze Brute"

 

[work2muchplay2little]

Eric, that truck is just WAY too clean. You need to give it a good mud bath once in a while. #ad
#ad
BTW, I like the looks of that diff. cover, gonna have to get one.

------------------
Kurt Voss
********* 1999 2500 24VCTD AUTO 4x4 QC LB Laramie SLT, Luverne stainless steel nerf bars, 3 piece bug deflector, mopar mud flaps, Line-X bedliner, Blue Chip Fuel Management System (Premium), Psychotty Air, DD3's,TTPM, DD 4" exhaust, HX40, DTT VB/TC(91%) , Mag-Hytec transmission pan... YEEEEEHAAAA!!
2000 4x4 Z71 Tahoe, all options, rear AC, brush guard, nerf bars, mobile video system, after market 3rd row seat... the ultimate urban assault vehicle!