Chunks in D44 diff..

[67eb_in_619]

So just upgrading the diff cover and while draining the oil, I found some good sized chunks of metal in the diff. There are about 15 of them all about the same size.. all about the size of a pencil eraser cut in half. I cannot see any damage to the ring.. the pinion has one little skuff on it, but doesnt look like the source of one of the chunks. The carrier is a Detroit.. I havent noticed any noise or anything. I have felt some significant bind when trying to turn in 4x4 under load, but with a detroit, I would expect that.

What are the chances I am chewing up a detroit? Suggestions on other sources for the metal? Any way I can verify that everything is ok? .. I had the gears changed a couple years ago.. didnt do it myself.. and I guess it is possible it is metal from the old setup, but kinda doubt it.

Thanks!

[cheapthrillb2]

sounds like a bearing took a shit...possible bearing from the pinion or the carrier

[94stepsideford]

sounds like a bearing took a shit...possible bearing from the pinion or the carrier

x2. Carrier or pinion bearing took a dump.

[67eb_in_619]

Everything rotates smooth.. These look more like teeth/splines than bearings.. but I am willing to be wrong given the cost of a new detroit.. or ARB since I cant NOT upgrade. :)

Here are some pics to help diagnose...
http://picasaweb.google.com/Matt.Putman/BroncoReferencePics

How bad will the flaming be if I cross post to jeep hardcore? I need to know if I am replacing this ASAP since I have a big run to go on that has been planned for months in 2 weeks.

[IROK Cherokee]

Those are chunks from the side gears. Have you broken anything else on this axle previously? You can buy the gears separatly.

[67eb_in_619]

I broke both front ujoints and my steering box .. then upgraded to chromoly's w/the Yukon Super joints.. I have wheeled it 4-5 times since then.. sometimes pretty hard. I have heard some "chunking" and felt more sporatic and severe steering bind.. but just thought it was the locker acting up. Guess it was metal chunks shearing off and causing the bind.. great. Are these side gears pricey? Will I need to have the front end setup again or can I just pull/replace/install?

[guidolyons]

I broke both front ujoints and my steering box .. then upgraded to chromoly's w/the Yukon Super joints.. I have wheeled it 4-5 times since then.. sometimes pretty hard. I have heard some "chunking" and felt more sporatic and severe steering bind.. but just thought it was the locker acting up. Guess it was metal chunks shearing off and causing the bind.. great. Are these side gears pricey? Will I need to have the front end setup again or can I just pull/replace/install?

Yup, looks like chunks from the side gears on the detroit. You can get replacement parts (side gears are ~$150-170ish), and if you keep track of the shims, etc you could remove and replace and everything *should* go back together and remain with in spec. It would be worth getting a dial indicator to check backlash and run a gear pattern check before and after to make sure.

There have been a few threads lately on busted detroits and getting replacment parts. At least one was by Vetteboy79 IIRC.
edit: found it:
http://www.pirate4x4.com/forum/showthread.php?t=608609&highlight=detroit

Another that has where to get parts: http://www.pirate4x4.com/forum/showthread.php?t=619710&highlight=detroit+parts+busted

[IROK Cherokee]

I broke both front ujoints and my steering box .. then upgraded to chromoly's w/the Yukon Super joints.. I have wheeled it 4-5 times since then.. sometimes pretty hard. I have heard some "chunking" and felt more sporatic and severe steering bind.. but just thought it was the locker acting up. Guess it was metal chunks shearing off and causing the bind.. great. Are these side gears pricey? Will I need to have the front end setup again or can I just pull/replace/install?
if you broke the joints, then it's 99% of the time going to take the locker with it. When you replace the side gears, you can have then cryoed, and that will help when it breaks again.

[67eb_in_619]

Have what cryoed.. the side gears?
Carrier is out.. that sucked!

[94stepsideford]

Have what cryoed.. the side gears?
Carrier is out.. that sucked!

Yup. But beware, detroits will do that when something lets go.