My Honda dealer's attempts to rebuild the diffy eventually failed. After admitting little or no experience with the setup of a RWD differential my car was subbed out to an off road specialty shop for proper setup. The case was opened up and the verdict was a replacement of the pinion and ring gears is in order. I'm now awaiting the final decision of the Honda DSM to determine if the whole thing can be replaced. What a mess, four months and counting over a differential problem and the grind TSB. Anyone else had this miserable experience yet?

 

Did they open up your Torsen diff? (You mentioned the gears inside the diff were ok). The service manual says not to open it.

 

[QUOTE]Originally posted by The Reverend
[B]Did they open up your Torsen diff?

 

The DSM had to authorize the "exploratory surgery" although I had hoped it would be replaced. I read the entire procedure from the factory manual left on the bench. The procedure for rebuild is illustrated and does of course involve opening the case. They did not dissasemble the Torsen unit contained within the case although all bearings and seals were replaced within the housing. The rebuild lasted two days before the moaning noises returned. The dealer sent the car out to an off road specialty shop to properly setup the ring and pinion gears. In the shops opinion the unit was not serviceable for reasons unknown to me. I saw the initial attempt in progress and other than a worn bearing no noticeable defect could be seen. The DSM finally authorized replacement of the entire assembly last week. My car awaits reassembly at the off road shop next week as the parts arrived late yesterday. I hope Honda stands behind the repairs. The car looks pretty out of place beneath the monster trucks.

 

Thank you for all the posts and contributions from the well known members on this forums. IT was very informative reading this thread.

I found this thread very useful and brought it back "from the dead"....and just a short message of appreciation

Thanks guys.