OK so now that people are worried about their diff, and especially those with superchargers, Who knows the Main reason for faliure?

That comptech one was said that the casing broke, If the casing is giving just a little bit that could throw off tolerances and cause wear/damage.

Short of replacing the whole Diff case and innards, if the gears were strong enough and the limited slip were strong enough, then the casing is the problem.

I've read that other thread but this one is going in a slightly different direction ->

Maybe the stock casing can be braced with a type of collar.
or a system of collars, a simple solution and I think weight would only be a few pounds depending on the material.

I think the case breaks as a result of the innards failing not as a cause of the failure.
Kinda like you get a hole in your engine block when you throw a rod (not a block problem).
I think ;)

Yeah, Im trying to understand the cause, as mine hasn't failed yet. I ask about the casing as maybe another contributor.

Maybe we could just find a complete rear Diff. IF one is compatable/interchangeable.

If it helps, this is from the warranty fix of my differential.

"Bent Pinion found, Clutch Pack in Carrier burned, replaced Ring, Pinion, Bearings, Carrier and Rotor. Parts included in the repair are (these each have different part #s)
PEICE, DI
SHIM SET
SPACER
BEARING A
BEARING A
OIL SEAL
GASKET
CIRCLIP
BEARING A
OIL SEAL
DIFFERENT
GEAR OIL
LUBRICANT
GEAR SET
If you like I will post the part #s for the above

There is no clutch pack. WTF are they getting this from? They need to stop thinking posi and start looking at what they are working with. THERE ARE NO CLUTCHES! I have picture to prove it (It's just taking me a really long time to sit down and take them off the DV camera :)).

f-
i guess I am showing my age, yes I listen constantly!(-:

I above repair involved the Axle Shaft as that is the title of the job, sorry I ommitted that. At the time they also did both tsb 55 and 54 and the parts for that are listed in a different location
for the tsb it states
replaced countershaft first gear and second gear set
installed updated clutch disc
parts used were
gear set
gear
sealant
gear
disk comp
fluid, mt

I supose the "pinion" spins inside the axle shaft and the bend caused damage to the bearings and the "clutch pack in carrier" ??? Can anyone explain this?

The torsen is known for using GEARS and not Clutches like the Reverend's KAAZ . . . So I have no Idea what they refer to.

The pinion would bend maybe when the diff locks.

And maybe the bearings were damaged by floating metal (If damage is inside the bearings) from the diff starting to fail.

But I wonder, elviscos, what events took place towards the end of you differentials life?

It is held as common beleif that (more critical in racing) only a VERY experienced tech should set the ring/pinion. Accelerated wear and early failure can result from the wrong tooth contact.

Of course how do you get the experience? lol


Reverend, it would be great to see some of those pics!

cmnse,
my car was definately not broken in according to the manual as it had been test driven by myself and I believe at least one other person before delivery. Stuid dearler insisted there was no break in period and that it was ok to go to redline. I asked! Boy was I pissed. Other then that, I like to drive fast. I do not abuse with clutch drops which I have done once on a sandy road. I have 6,000 miles. Anyway my differential was no problem for me until.... I went in for the tsb's. The dealer found metal in the fluid. Not liking this they replaced it with fresh and then the problems/noise started. The diff was making definate loud noise that was not present before.
Evan

hmmm I have my rear deck out for a stereo install and can hear what sounds just like the brakes dragging regardless of brake application, I discount it as normal for now.

Your problem really sounds like the pinion was misaligned.
Not breaking it in correctly would shorten its potential life BUT would rarely be the cause of such a failure.