On the way to work today after a short 4th gear pull to 7k on the freeway.. I noticed a loud howling noise under load. Then a short distance later it turned into very loud knocking. I am almost certain that the diff finally went, I have had all kinds of noise coming from it for the past 20k miles or so but I still haven't got under the car to verify.

Looking for some advice on the best route to take here. I think I am going to tackle at least the removal and re-install myself to save some money... considering my baby girl will be here in a few months. Have any of you guys removed a diff? Was it worth it to DIY?

Also, considering that I stopped driving it before it exploded... is there a chance that I can have it rebuilt with some kia gears? I wouldn't mind changing the ratio while I am at it.

My car is falling apart!!!

 

I've been there buddy. I'm chasing down some issues myself. I've R/R my diff a couple times and IIRC it was pretty straight forward. The last time was a few years ago and I managed to R/R by myself then bring it into a shop to have it built. I'm pretty sure there is a DIY thread somewhere on the forums here.

Of course everyone is going to recommend SoS to build it, but let me tell you right now that apparently they are booked up until the end of May. Maybe you could try some of the local 4x4 shops? If you need a hand, LMK and just remember that the pumpkin is HEAVY!

 

Pick up a new or good condition used diff,

drive it tame, swap it on the lift at the BBQ meet.

 

That's a good offer right there!

 

I wish I could but the diff is probably about a mile away from being completely locked up. That is the worst part about this!! Just a few days prior I changed my transmission fluid and flushed my clutch fluid in anticipation for the cruise on the 24th. Looks like I am going to miss out on the biggest group event since the last Fun the Sun or whatever it was called. which I also missed.

I had the car towed home today and put it on stands. It is certainly the diff. After reviewing some of the DIYs and looking at it today, I am confident that I can pull it out on my own. Then I think I'll take it to Dave at Advanced Auto to weigh out a rebuild vs used. Apparently they specialize in diff work and he used to road race an RX7 so I figured I would drop it off to him and tell him that its one of his team's POS Mazda parts

 

Got the diff out today and dropped it off to Dave. Everything went smooth except for pulling axles out of the diff, that was a major PITA. He is going to pull it apart tomorrow and see what needs to be replaced. I'm gonna go with the Kia 4.77 ring and pinion, for the price and for the gearing reduction. I also might have him tap the diff for a temp gauge sender.

 

Dude, you are going to love the 4.77s. Let us all know how the rebuild goes and don't be such a stranger!