Help, Metal chunks found in axle

[intentsrig]

Pop that cover off and see where the piece is missing from

Looks like the big ring gear. Not the spider gears to me. Really surprised you don’t have the lsd. Mine was rounding my spider gears because the clutch’s inside were already wearing out. Big issue in the jk as well that lead to broken ring gears/ spider gears.

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[YY1985YY]

Pop that cover off and see where the piece is missing from

Looks like the big ring gear. Not the spider gears to me. Really surprised you don’t have the lsd. Mine was rounding my spider gears because the clutch’s inside were already wearing out. Big issue in the jk as well that lead to broken ring gears/ spider gears.

Question, if you haven't posted about it yet, but how did you find out you had issues before opening it up, fluid change with chunks like me? Or was there any physical signs/vibrations while driving?

 

[jessedacri]

Typically yes! new gears should be given a break in period.

Pop that cover off and see where the piece is missing from

Looks like the big ring gear. Not the spider gears to me. Really surprised you don’t have the lsd. Mine was rounding my spider gears because the clutch’s inside were already wearing out. Big issue in the jk as well that lead to broken ring gears/ spider gears.

How many miles / how much wheeling did you do on the LSD before this happened? Curious for a buddy's Sahara which we've put through some serious challenges.

 

[intentsrig]

How many miles / how much wheeling did you do on the LSD before this happened? Curious for a buddy's Sahara which we've put through some serious challenges.

At least once a month sometimes more. All on 35’s or 37’s

 

[intentsrig]

Question, if you haven't posted about it yet, but how did you find out you had issues before opening it up, fluid change with chunks like me? Or was there any physical signs/vibrations while driving?

I could feel a noticeable clunk when letting the clutch out from a stop. The clunk was play in the spider gears caused by a lack of tension due to the lsd clutches wearing out.

And every time I did a diff change the fluid was black and nasty. Because of the clutch packs breaking apart. I’m talking like black and nasty after 1200 miles. I could go 8-10k with my jk dif fluid and it would come out looking clear and new.

 

[oceanblue2019]

I'm concerned because I found two 1/2" metal chunks after changing my rear axle fluid (def not your typical metal shavings). I will be contacting my dealer as I have the V41 recall coming up at the end of the month. Was this my fault, did I do something directly to cause this??

Lastly, does anyone know how serious this is and what I should be prepared to tell my dealer? I saved the pieces and thought maybe someone here could give me some input. It should be covered by warranty correct?

Take a good look at the chunks - do they look like they are casting flash or excess stamped steel? Also do they look like they have any abrasions on them?

 

[YY1985YY]

*Update~
So after dropping off my Jeep at the dealer, they were a bit skeptical at first of my claims which bothered me, claiming "how do we know you didn't cause the damage yourself?, If you did it's not covered under warranty.." which irked me, but they said they would check it out. Later on in the day, I get a call from them (to confirm and agree) that if they open the rear differential and find "nothing unusual" I would be charged $350 in labor fees.. I had to reiterate that although I'm no mechanic that these metal pieces definitely came out from the rear fluid, so if you "find nothing" I would want a different technician working on my car because I'm positive there's something broken in there (even though they "heard nothing unusual" during testing). So they follow up with me later on in the day telling me, they found nothing at first.. (seriously....?, My blood started to boil but I wanted to remain civil with them). So the tech then took a magnet to the differential and lo-and behold!, more metal pieces were found, so my claim is now valid and I don't have to pay for labor.
I was told that they would replace the component that contained the spider gears and what not but not the entire differential because that all seemed fine. Now I have to wait for parts and hope they fix it properly, fingers crossed*

TL;DR
Dealer doesn't find anything unusual or broken until a magnet is used to find more metal pieces. Says they'll replace whatever holds the spider gears and such, but not the entire rear axle.

 

[Glamisfan]

I’d tell them to replace all components because that large of metal can damage everything in there, especially the bearings. If they refuse, run it higher up the ladder till they agree!

I’d also insist that I be allowed to look at the parts with magnifying glasses and a flashlight to look for damage. I’d tell them that’s my defective vehicle and I wanna see for myself what’s going on in there.

 

[intentsrig]

*Update~
So after dropping off my Jeep at the dealer, they were a bit skeptical at first of my claims which bothered me, claiming "how do we know you didn't cause the damage yourself?, If you did it's not covered under warranty.." which irked me, but they said they would check it out. Later on in the day, I get a call from them (to confirm and agree) that if they open the rear differential and find "nothing unusual" I would be charged $350 in labor fees.. I had to reiterate that although I'm no mechanic that these metal pieces definitely came out from the rear fluid, so if you "find nothing" I would want a different technician working on my car because I'm positive there's something broken in there (even though they "heard nothing unusual" during testing). So they follow up with me later on in the day telling me, they found nothing at first.. (seriously....?, My blood started to boil but I wanted to remain civil with them). So the tech then took a magnet to the differential and lo-and behold!, more metal pieces were found, so my claim is now valid and I don't have to pay for labor.
I was told that they would replace the component that contained the spider gears and what not but not the entire differential because that all seemed fine. Now I have to wait for parts and hope they fix it properly, fingers crossed*

TL;DR
Dealer doesn't find anything unusual or broken until a magnet is used to find more metal pieces. Says they'll replace whatever holds the spider gears and such, but not the entire rear axle.

$350 to pop open the rear diff cover?! That’s insanity.

 

[YY1985YY]

I’d tell them to replace all components because that large of metal can damage everything in there, especially the bearings. If they refuse, run it higher up the ladder till they agree!

I’d also insist that I be allowed to look at the parts with magnifying glasses and a flashlight to look for damage. I’d tell them that’s my defective vehicle and I wanna see for myself what’s going on in there.

I would love to do this, as I have a bit of OCD, but I doubt they'll be responsive to my request, doesn't Hurt to try I guess.

Anyone know if the spider gears and other bearings are contained within a closed component or would the metal pieces be flying around anywhere in the differential cover?

 

[YY1985YY]

$350 to pop open the rear diff cover?! That’s insanity.

Yea it blew my mind, saying it would take at least 2 hours of labor... To take it off. I'm just glad they covered it under warranty but still makes me skeptical of my dealer's motive & mechanics.

 

[YY1985YY]

Does anyone here have a diagram of the component that houses the spider gears for the dana44 open diffenrential? I'm trying to get a visual of what my advisor is replacing, and if I need to stress a more thorough inspection. My warranty will expire in less than 1,000 miles, so I don't want to be out of warranty if they only replace the "broken parts".

 

[Glamisfan]

The metal pieces fly around everywhere that the oil goes. Normally that includes all the way out to the wheelbearings. that’s why everything should be replaced because it’s been contaminated with metal particles. The axles themselves will be OK but their bearings should be replaced. And most likely those metal chips came off of either the ring gear or the pinion gear and those are always replaced as a set.

 

[YY1985YY]

*2nd Update
So my dealer told me that they're replacing the "carrier" and anything within that carrier housing (spider gears, etc) but not the entire Dana 44 rear axle. Claiming everything else "looked perfect", is this okay? They kept mentioning that the extra metal pieces (not including the ones I found) were on the bottom of the drain plug where the magnet is and that nothing else was compromised. Is this an acceptable solution or do I need to stress the issue more and make the FCA/ dealer replace the whole rear differential completely?

The advisor kept saying only a replacement carrier is covered under warranty in this situation, but I'm worried about my warranty running out in 1000 miles on every other part.

 

[YY1985YY]

The metal pieces fly around everywhere that the oil goes. Normally that includes all the way out to the wheelbearings. that’s why everything should be replaced because it’s been contaminated with metal particles. The axles themselves will be OK but their bearings should be replaced. And most likely those metal chips came off of either the ring gear or the pinion gear and those are always replaced as a set.

They told me the damage was on the bearings as you claimed.

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