Detailed Quaife install question...

[CoolVanilla]

Ok guys, question:

We're in process of installing my new rear diff, and just ran into an issue. We removed the 3rd member and found an oops by Dodge; one of the mounting bolts from the rear cover to the chassis is longer than the depth of threads. When the bolt was removed, all the threads came with it.

Is this common, or am I the lucky one?

Rather than just replace the cover, we're going to machine the old cover and add thread inserts. Gonna give us a stronger connection anyway, and we'll be able to set the proper bolt depth for sure.

The other bit of 'good' news is that when we spin the pinion, it feels "crunchy". So we're gonna do a complete inspection and see what's up.

Never ends eh?

[CoolVanilla]

Click here (https://backup.filesanywhere.com/v.asp?v=%89ke%8F%5Bd%A1%B1%9Ei) for a couple of pics.

[lafrad]

Running a bolt into the bottom of the threaded hole is something that, unfortunately just happens. Sometimes the drill/tap don't run down far enough, sometimes the wrong bolt is used... sometimes its just a tolerance issue...

Drill the hole a little bigger, tap it, and heli-coil it. Those are STRONGER than stock, do to the unique way they bite into the metal.

The fact that your bearings aren't smooth concerns me: I wonder if we are starting to see what wear is caused to the drivetrain from engines that make more power... I wonder what the lifespan is on those bearings with 450 rwhp :doh:

Imagine how much worse it would be with a set of gears?!?!?

[Super T]

When you spin the pinion, is it connected to anything? Are the planetary gears or the driveshaft in? If it's just the pinion and it feels crunchy, then you gots bearing issues I'd imagine. Bummer :-(

[CoolVanilla]

Everything is out, sitting on a table, not connected to anything. Still investigating, but it sure seems like a bearing issue...

[Super T]

That's no good. If you really think about it, given the way a differential works... there's not an excessive amount of load on that bearing. I mean the shaft is pretty much held center by the gears... it's not like there's a ton of force pushing in any one direction on the pinion, just a torque. So then what fries the bearing??? Could it be a heat issue? Do these cars have diff fluid temp sensors?

[MattRobertson]

Dude you are just the lucky pioneer.

With 56k miles on my tranny and the way I have driven it, I can't help but wonder what mine looks like.

[Jaak]

Well, better to find it now, then have it barf it's guts later and take out something you just bought.

PITA, sorry it's happened to you, but happy you've found it. I'll check mine when I get there.

[CoolVanilla]

Dude you are just the lucky pioneer.

...sorry it's happened to you...
Bleh thanks guys, but why not me? Rather find out this way, on the rack, than... elsewhere. Hopefully we can learn something from this, and maybe someone that sees this will avoid an issue later. Clearly anyone installing a Quaife ought to take a quick peak and see since your there already...

Looks like we're gonna replace it. If we do, I'll get it cleaned up and see if we can see marks or scarring.

[lafrad]

Well, you have been saying alot of the "I'd rather find it now than later" things...

All I can say, is, UG.

[MattRobertson]

"replace it"... what it is being replaced, and give us time and parts guesstimates? I'm thinking a lot of us Ricky Racers are in this boat whether we know it or not. Mine is getting opened up in the next month or so, so we'll have a second example to look at soon.

[CoolVanilla]

Looks like we're gonna replace it. If we do, I'll get it cleaned up and see if we can see marks or scarring.
Welp after a through cleaning and a lil love, she went back together and is movin smoother than she did the day she was born. No replacement needed.

Still though, if you're going to be in there anyway, take a peak.

[Jaak]

Great news!!!

I'm looking forward to hearing your feedback on it. Lately I've been turning the ESP off a lot, as it annoys me when it chokes the engine and puts on the brakes, just because the tires slip a little.

[Super T]

So what was the issue, dirty lube?