Hi all, unfortunately on the way to get the S2000 smogged, had the rear end blow. Small vibration -> large vibration -> bang -> problem. Unsure of the cause but suspecting diff bracket failure. Now looking for advice on how to proceed with a repair or any additional parts that may be needed.

Damage looks to axles, diff, diff bracket, and driveshaft (pictures below). The diff is resting and lowered slightly due to the broken bracket. driveshaft looks bent, and the bucket for the axle (driver) is torn. Diff mounts themselves look fine.

For now I believe I will need to source:

1. Diff bracket - are there differences between AP1 and AP2?
2. Axles - Just going to warranty these Autozone axles to get the car running ASAP
3. Driveshaft - Secondhand ebay?
4. Diff - Unsure if there is damage to itself or rebuild is possible. May also upgrade to OS Giken to reduce headache.

For repair I am thinking of:

1. Handbrake on, crack driveshaft bolts (hoping the passenger axle which is still connected is good enough - and that I can still rotate the driveshaft)
2. Undo axle nuts
3. Remove exhaust brace/exhaust
4. Remove rear sway bar
5. Remove axles
6. Undo diff mounts or whats left of that bracket
7. Remove diff
8. Remove driveshaft
9. Replace everything in reverse order

Anything I am missing? Happy to provide any additional information as well.

Diff Bracket:


Driveshaft:


Axle/Axle Bucket (Driver):

 

Video of the underside:

 

Sorry, it looks like a possible complete rear-end job.

What caused that? Did you spin the rear, then hit perfect traction?

Good luck with the fix!

 

It was a sudden failure, I was going about 50-60 mph and turning a gradual right when the vibrations happened. I’m not boosted or tuned so I’m surprised this happened in the driveshaft area.

 

Looks like a mess

 

There were no warning signs? Was the rear end or the drivetrain ever worked on before?

Such sudden catastrophic disasters are kinda rare for Hondas.

Anyhow, good luck with the fix!

 

Looks like pinion failure

 

Now that you mention it there was a whirring sound that came from the rear end, and looking into pinion failure (thank you noodels), it seems that was the cause.

I originally thought that this sound was coming from the trans and had some stuff on the way for that.

Looks like that OS giken will be the way forward!

 

Update, was able to remove most of everything. Need ideas now on how to remove the driveshaft, it was completely destroyed so the handbrake can't hold it in place. See image below:





Other pics of damage:

 

When the crush sleeve fails and the pinion starts moving, it typically will start making a noise on decel for a few minutes before it is dead completely. It could have caused lockup in the diff and then failure of the rear CV joint on the prop shaft. It is possible that the diff brackets had damage and failed, causing misalignment which caused the pinion to fail too I suppose.

For the prop shaft, try putting the car in gear and moving the bolt you are trying to remove to the bottom , then in neutral, turn to the next one, etc. You could also place a long breaker on the crank bolt and have someone hold it to help prevent it from turning over while loosening them (or if by yourself turn it until the breaker rests on the frame to hold it) If you make sure they are cleaned out very well and have a good allen socket tapped in there all the way you can even bump them with an impact. If that does not work, try using a ratchet strap around the prop shaft and that loop that keeps it from hitting the ground if it breaks. Cinch it tight and it likely will hold well enough to get them loose

Diff is trash most likely after that failure. Look for a used one

Need a used prop shaft unless it magically did not damage it bad enough that you cant rebuild the CV joint but it looks trashed to me. Find a used one

Diff mounts, large diff bracket, etc of course are all trashed.

This is a pretty bad failure to have just happened like that. I have trashed a diff on track due to a crush sleeve failure and just replaced the diff with my spare and went on with life. I suspect there was something else that led up to this to fail this catastrophically.

As an example of the typical noise you hear if the crush sleeve happens, I am linking the video below. Sorry, it is a video of a video because Catalysts stupidly only export complete laps and I never crossed the finish line so had to literally video it off the catalyst screen. Kinda hard to hear at first because of the other noise, but note that it sounds normal, then the noise starts up each time I lift for a corner, until it lets go. That is the pinion backing in and out until the misalignment of the teeth cause it to destroy itself. Was actually harder to hear with my helmet on and the fairly loud vette I was catching. I at first thought the noise was his car until I realized it was not!