Kersplosion

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Joined
Dec 8, 2006
Threads
447
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12,691
Location
New Jersey
Website
www.sdsysdesign.com
So last Saturday evening my son Josh took the truck to pick up some of his buddies. I get a call 15 minutes later saying he’s stuck a few blocks from home. I get there and there’s police everywhere, kids all OK standing on the sidewalk. I walk up to the truck and there’s 30’ of skid marks from the 2 front tires and motor oil is pouring out of the pan. WTF?

Josh said he heard a loud growling sound and then BAM. It locked up and made some bad banging noises. I looked under as best as I could between the cops asking for my paperwork and trying to keep everyone calm. The side of the oil pan was wrecked by the flailing companion flange that was hanging on the end of the front driveshaft. Hmmm, I thought. This doesn’t look good at all.

Flatbed to my house and drop it in the driveway. Had a client on Sunday morning so in the afternoon I pulled the front drive plates and got it trailered to Dave Crum’s shop. Today I pulled the entire front end apart and was able to inspect the damage. The R/P is done, the ARB is done, and the housing is done.
The companion flange took out the oil pan, transmission cooler lines, fuel filter and rear fuel line, and chipped the flange mating surface of the diff housing so it looks like it’s been chewed on.

I think that somehow the pinion nut backed out and it just dropped in. What a freakin’ mess. Here are some pictures for your amusement.
diff 1.webp
diff 2.webp
oilpan.webp
 
What does the housing look like?

Holy s*** man, that's a lot of damage. I've never seen that before.
 
:eek: wow man. Sorry :(, glad all were ok, but suck about the truck.
 
A lot worse than I thought Jon from your email description.

Best course of action is going to be looking for a used housing and then begin anew with new innards.

Man.
 
All time carnage record on an R&P. Wow. Hope/glad they were wearing seatbelts, cause that had to be one heck of a surprise stop dragging the front tires.

DougM
 
Here's a shot of the housing before we pulled it down.

Oh, you mean just the 3rd member. I thought you meant axle housing. Still, holy s***. If the end of the pinion is intact ( looks like it is ) then I would definitely suspect the nut backing off.
 
Yup, pretty scary. Josh was shaking pretty good both from adrenaline and "fear of dad". I diffused the moment as best I could. No one was hurt, no other vehicles were involved. It all just parts and labor now.

4.88s here we go!
 
Jon,
Yes, very lucky, things could have been much worse. And they are sure bad enough.

I was driving dad's 63 Olds one night while we were stationed in Germany and he was away TDY in the early 70s. :steer: I'd just dropped off the autobahn after visiting a GF at another base. I'd been tooling along at the usual 70 mph+ just moments before, taking the exit up to the stop sign to enter the road up to the base.

It just sat there, wouldn't move away from a stop. :confused: Made a phone call, told mom to bring a chain and the station wagon. Hooked up to and started to pull the Olds and the entire rear wheel pulled away on one side, dropping various parts on the ground. turned out we'd need a tow truck after all.

WTF? Broke the axle. If it'd happened 10 seconds sooner, I'd been in big trouble, because if you're a teenager there was no reason to drive slow on the autobahn, even with the gas crisis on:p

My problem wasn't so obvious at first, but I think I know how your son was feeling. Good on him that he got things "under control" as much as that was possible and no one was hurt.:cheers:
 
Glad that everyone was OK, and it sounds like you have the rebuild pretty much lined up.

Reminds me of when I was 16 sitting in the passenger seat of a buddies dads' coveted CJ5. He was popping wheelies in the school parking lot, then bang the rear diff went in spectacular style. No worries, put it into 4wd and maybe we could get 'er home...duh the diff was seized. :hillbilly: What was a screw up on his part became the excuse for his dad to upgrade to a Limited Slip Diff...OK it was the 1980's. Not sure how much crap he took, but I do remember him having to pay a good portion of the repair build.

:cheers:

Steve
 
Wow. :eek:

Jon,

My only online memory of your son is from when you dropped your 80 through an icepack and had to pull him out of there before the rig sank. (Can you laugh about that one yet?)

I can't believe he's driving now; glad everyone's ok.

Tempus fugit...
 
Kudo's to your boy for keeping it shiny side up! thats had to scare the crap out of him.
 
Wow, your description to the mailing list was nothing like the carnage I see in the pics, that's crazy!
I've seen Josh drive on the trails for the last few years, never on the street. Given the damage, I'm glad he and his friends are ok. I'm not sure that I wouldn't have hit something myself.
What ratio is in the pinion?

(We still don't talk about the I c e)
 
If the end of the pinion is intact ( looks like it is ) then I would definitely suspect the nut backing off.

How does this happen and how does one prevent this from happening again? The gearset was changed to 4.56 along with an ARB back in 2004. Has not been touched since. The complete 3rd was pulled 2 years ago, but the pinion nut was never touched.
What could have caused the pinion nut to loosen?
 
How does this happen and how does one prevent this from happening again? The gearset was changed to 4.56 along with an ARB back in 2004. Has not been touched since. The complete 3rd was pulled 2 years ago, but the pinion nut was never touched.
What could have caused the pinion nut to loosen?

Maybe the pinion nut wasn't notched enough and eventually it started to come loose?
 
"How does this happen and how does one prevent this from happening again?"

Perhaps a part time conversion is in order...
 
How does this happen and how does one prevent this from happening again? The gearset was changed to 4.56 along with an ARB back in 2004. Has not been touched since. The complete 3rd was pulled 2 years ago, but the pinion nut was never touched.
What could have caused the pinion nut to loosen?

I really do not know. Like slow91 said, maybe there wasn't enough staking on the nut, allowing it to bend the staked portion out over time. Was there enough fluid in the diff before it went? Maybe the pinion bearing started going, producing vibrations which forced the nut to back off, regardless of staking.
 

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