Front end Differential

[Eric90242]

This weekend I went out camping and had to engage the 4wd on my truck. After I engaged it into 4wd Lo I drove about 15 ft and started hearing a loud poping noise coming from underneath the front end. I took it to a GM independent shop and they found the front Differential Housing cracked. The truck was on it's second trip after having 4.56 gear installed in the front and rear. The mechanic at the shop said the problem may have happened due to the shop that did the gearring possibly under torquing the bolts cause the internals to come loose and cracking the front differential case. Now I am dealing with a $1,900 repair job and trying to convince to gear shop that it was their fault. The truck only has 20,000 miles, it's a 2002 Chev Silverado 1500HD 4x4.

 

If anyone knows where I can get a deal on a front differential housing case please let me know thanks.

[vhato]

This weekend I went out camping and had to engage the 4wd on my truck.  After I engaged it into 4wd Lo I drove about 15 ft and started hearing a loud poping noise coming from underneath the front end.  I took it to a GM independent shop and they found the front Differential Housing cracked.  The truck was on it's second trip after having 4.56 gear installed in the front and rear.  The mechanic at the shop said the problem may have happened due to the shop that did the gearring possibly under torquing the bolts cause the internals to come loose and cracking the front differential case.  Now I am dealing with a $1,900 repair job and trying to convince to gear shop that it was their fault.  The truck only has 20,000 miles, it's a 2002 Chev Silverado 1500HD 4x4.

 

If anyone knows where I can get a deal on a front differential housing case please let me know thanks.

 

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The housing is a turd, and it is possible for it to crack with over/under torqued bolts. Most places use an impact wrench since it is next to impossible to use a torque wrench on it without it wobbling around.

 

However, I have never heard of one cracking. The housing has 2 weak points, the upper mount and case half. I am not trying to say the GM Shop is lying, but maybe they are unsure and are confident by replacing the whole thing your problem will be solved. Parts of the case half have MANY cracks in the outer side anyway leading one to falsely beleive it is cracked when it is not.

 

What Cracked?

 

1. 1 of 2 case havles?

2. Passenger Axle Tube?

3. Upper Mount?

 

I am just curious. Good luck trying to find one. The AAM 925 Axle isn't an esy find. Any junk yard with a 2500/3500 from 1996-2006 will have one that will work......but without 4.56's.