CV popped out of front diff??

[ZG MN]

Hey All-

This morning as I was parking at the dog park, I suddenly lost all forward and backward movement and had mild grinding noises when shifting into D or P. Thought i had destroyed the transmission/t-case somehow.... but after looking under the rig the passenger side CV was popped out of the diff. After 2 quick calls to Slee (they've been awesome every time I've called) I limped it 8 miles back home with the center diff locked and no strange noises/etc.

Currently ripping apart that corner to pull the CV/install a new one and drain & fill the diff. This one had been installed 3 weeks ago....not OEM.

What would have caused this? Did I not fully seat the CV during the initial install? I'm super confused.

Thanks!

 

[TheForger]

Look at the condition of the inboard c-clip, that’s what holds the axle in the front diff

 

[Trunk Monkey]

Pop off the dust cap, bet your c-clip came off. You'll need to make sure you have the correct thickness so it doesn't happen again with the non-OEM CV. You can get a pack of all the different thicknesses from Cruiser Outfitters. You'll also need to check that you didn't grind the splines off the CV or flange.

 

[ZG MN]

Pop off the dust cap, bet your c-clip came off. You'll need to make sure you have the correct thickness so it doesn't happen again with the non-OEM CV. You can get a pack of all the different thicknesses from Cruiser Outfitters. You'll also need to check that you didn't grind the splines off the CV or flange.

Based on the small amounts of debris in the diff, I'm pretty confident that I did some damage to the CV, but thankfully I have a cheapo trail spare on hand with a ring from an OEM. The snap rig was still on there, but I'm guessing it was far too thin. Just ordered the various thickness kit you suggested, thank you.

I'll keep y'all updated!

 

[Trunk Monkey]

A small amount of shavings on the magnet is normal, chunks are not. Never heard of a CV failing on the diff end.

 

[ZG MN]

A small amount of shavings on the magnet is normal, chunks are not. Never heard of a CV failing on the diff end.

I fully flushed the diff with 3 qts of random 75/90 I had sitting around, and have let it air out & drain since lunch. CV is out on the diff side, and knuckle is completely disconnected from the rig save the brake line and is sitting on a chunk of wood safely with the help of a scientific amount of bailing wire. I'll yank it out of the knuckle and post my findings in a bit.

Of course this happens on the day I WFH for once.

 

[ZG MN]

As suspected, there was noticeable damage to the inboard splines on the CV. The retaining ring was also crimped at a non-round angle. Combo of not seating it properly and the wrong size snap ring.... thankfully no damage to anything else.