twisted diff on axle housing

[wdesignjc]

I have a serious problem. I tried to turn around on an icy forest road yesterday afternoon and got stuck in a ditch on a steep grade. In 4, low-range, I was able to get it unstuck with my brother pushing in back. But in the process, the differential spun off the axle housing and took the drive shaft with it. Everything still rotates, but it sounds terrible!

Any comments would be much appreciated. I'm wondering if the rear differential is probably still okay, and if this would have damaged the front diff at all, being it was locked with the rear at the time.

--jc

[IrishChef]

Well, first off, Merry Christmas. Sorry to hear about your axle. But perhaps now is the perfect time to up-grade your axle, seeing that you'll be putting some time and $$ into it anyhow. A nice D44 or 8.8 with disc brakes would be nice.

[AlohaBra]

[quote=wdesignjc]I have a serious problem. I tried to turn around on an icy forest road yesterday afternoon and got stuck in a ditch on a steep grade.

In 4, low-range, I was able to get it unstuck with my brother pushing in back.

But in the process, the differential spun off the axle housing and took the drive shaft with it.

Everything still rotates, but it sounds terrible! Any comments would be much appreciated.
I'm wondering if the rear differential is probably still okay, and if this would have damaged the front diff at all, being it was locked with the rear at the time.

--jc[/quote]

I think what you are saying is the rear spring perches came unwelded from the rear axle housing...is this correct? If this is the case, I think the diff it self is OK....you can have the perches rewelded.

Any other damage would depend on what else happened ....did you drive it home? Is the driveshaft bent?

I think the front diff is OK. The transfercase does the four wheel drive lockup.

[wdesignjc]

AlohaBra,

By spring perches, do you mean the u-bolts that hold the axle to the nut plate on the leaf springs? If so, this is not what broke. The diff actually turned about the axle housing. You can see where the welds holding the diff to the axle housing actually broke through the housing and turned around the shaft. They ripped through and tore a rotating line around the shaft. The u-joints are at a 90 degree angle to the drive shaft, as opposed to being like normal--in a straight line.

Glad to hear the front diff is probably still okay. I think the drive shaft is okay. I drove it off the mountain--stayed under 5-10 mph. My brother had a trailer that we hauled it off with once we hit the valley floor. Thanks for the advice so far.

--jc

[AlohaBra]

Sounds like your axle housing broke at the center section.

You can probably get one at the savage yard and swap everything over or just use that one if the gearing is the same...the rest of it is probably OK since you drove it.

[wdesignjc]

Yeah, that's what happened. I would like put a beefier axle on, but can't swing that right now. Probably will pull one from a salvage yard for the near term. Thanks for the help.

--jc

[Ray H]

The diff rotating like that is a really unusual thing for a stock Jeep. Even with the weakish D35, something else generally gives way before the housing rotates. I was skeptical at first that this is what happened to yours. My first thought was that your springs had wrapped and pointed your pinion up.
Forgive me if Im still skeptical, Ive only heard of this happening maybe one other time to a Cherokee and he was locked with 33" tires if I remember right. You do know that the diff housing isnt really welded to the axle tubes, right? Its a press fit so there wont be any broken welds
Anyway, if it is the case, your rear axle is toast. Your Jeep may have a D35, a 27 spline Chrysler 8.25 or a 29 spline 8.25. it doesnt matter. Get yourself a stock 8.25 rearend from a 97+ XJ with matching gear ratio and it will bolt right in. Your front axle should'nt have been effected.

[wdesignjc]

Ray H,
Didn't know the diff was pressed, not welded. I would take a picture to show you, but the Jeep is over at my brother's right now sitting on his trailer. I have slightly larger tires on than normal, nothing serious...30x9.50 R15's. The Jeep was in a bind, though. When I opened the hatch in the back, it would not close and latch since the rig was so out of square. I will look for an axle '97 or newer. Thanks for the info.
--jc

[wdesignjc]

Well, I tried to fix it cheap; that didn't work. The local mechanic spinned the diff back into place and double-welded it. That might have worked if it were lined up exactly. But now I have a vibration in the rear that gets worse especially above 55 mph. And now the ABS light is on; don't think it's working. Any ideas why that might be?? Think it's time to swap out the axle assembly. Thanks for any input.

--jc

[fredjacksonsan]

New axle time, it's likely it'll never be the same - as in true - again. If it was me, it would be Dana 44 time. Then you won't have to worry about it any more.

But if price is a consideration, junkyard's your best bet.

[IrishChef]

A nice Exploder 8.8 ('95+) will get you a much stronger housing and ring gear(8.8" vs. 7.5"), plus discs, 31 spline axles....oh, and the same bolt pattern,too.

[wdesignjc]

Thanks for all the feedback. The specs on axles are helpful. I will keep that in mind when I go to pick one up. Best.
--jc