Front diff making metal

If you have silver metal slivers rather than just the soft collective mush on the magnet and if you have silver slivers in the oil then it’s likely that your bearings are wearing and this is the initial plating on the running surface or on the roller bearings themselves.
Needs a rebuild of at least the output bearings (the ones most likely to be failing).
The cost of the bearings is low and new oil seals. Only extra cost is time as it sounds as though you would be able to do the work yourself.

If you have the main pinion besting off, you’re likely to need a new crush sleeve which seems very hard to come by!

Bodsy said:

If you have silver metal slivers rather than just the soft collective mush on the magnet and if you have silver slivers in the oil then it’s likely that your bearings are wearing and this is the initial plating on the running surface or on the roller bearings themselves.
Needs a rebuild of at least the output bearings (the ones most likely to be failing).
The cost of the bearings is low and new oil seals. Only extra cost is time as it sounds as though you would be able to do the work yourself.

If you have the main pinion besting off, you’re likely to need a new crush sleeve which seems very hard to come by!

Click to expand...

haven't dove into it yet but seems like quite the task just to remove the diff from the car. ive never rebuilt one so unfortunately I think this would be a job for a shop. I haven't noticed the noise in a while( probably my mind blocking it out knowing its going to be an expensive repair) so I think this will have to wait till after a transmission service, air compressor/air bags replacement and vacuum pump oil leak are fixed... credit card is getting a work out this month

[QUOTE="Bodsy, post: 191028, member: 35139"If you have the main pinion besting off, you’re likely to need a new crush sleeve which seems very hard to come by![/QUOTE]

Noise is slowly getting worse so decided to order a bearing kit and rebuild it. Ordering the kit tonight and hopefully doing it thisweekend. Does anyone have experience on this or advice?

Mine started to grind a few months ago (approx 105k). First thought that it was the wheel bearings so I replaced them. They had a slight play, but weren't causing the vibration and noise.
Got the bearing rebuilt kit a couple weeks ago but haven't been able to find time. I'm hoping to start on it this weekend.
Can't seem to find any "How To". Hopefully someone on here can help.

Huy Tran said:

Mine started to grind a few months ago (approx 105k). First thought that it was the wheel bearings so I replaced them. They had a slight play, but weren't causing the vibration and noise.
Got the bearing rebuilt kit a couple weeks ago but haven't been able to find time. I'm hoping to start on it this weekend.
Can't seem to find any "How To". Hopefully someone on here can help.

Click to expand...

My kit arrives today so install is tomorrow, I’ll try and take photos and do a write up on it( usually get busy with actually doing the work that I forget to take photos lol)

Day 2 of this rebuild and I’m about to throw in the towel. Removing the diff was straight forward but a huge pain! Split the case and immediately saw the bearing that was bad but they are almost impossible to get off, I’ve got one side left to do but there is just nowhere to get a punch or pulled to remove them. I’m definitely way over my head on this so unless you’ve got experience rebuilding diffs and specialist tools then I wouldn’t attempt it. In the photo is the bad bearing. As you can see it has to be pulled off somehow but there is nowhere to place a puller. Pulled the roller sleeve off hoping to get it on the little lip around the top edge of the bearing but no luck. Ended up taking 2 hours and carefully cutting it off( somehow without hitting the shaft it sits on) maybe I’m dumb and you can find a better way or get the right tools

That looks like tough bearing to pull. I would not attempt that without a special fixture.

Don't give up. You've got the hardest part.
You'll need a bearing separator.
I bought one from Harbor Freight ($40 with coupon) in preparation for this job. Didn't get started tho.

Krill said:

My kit arrives today so install is tomorrow, I’ll try and take photos and do a write up on it( usually get busy with actually doing the work that I forget to take photos lol)

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Hey Krill,
Did you have to move the transmission oil cooler like the manual says to do? Does it get in the way of one of the mounting bolts?

Yes it’s a ***** to undo but I unscrewed the mounts from the frame and just pushed it up out of the way. Didn’t want to unplug anything. I actually had to cut that front diff mounting bolt to get it out because the nut side was just spinning and I couldn’t get anything to hold it but putting a new grade 8 1/2 bolt was easy and the nut locked itself in place. I thought I had a pic but if I pull my skid plate off today I’ll send one