Today I was on I-40 in Raleigh about to make an exit and downshifted to change lanes to make the exit and this very loud banging started, and a cloud of smoke appars behind my car. Being as it also stops pulling I pull over to the side of the road, get out to take a look, and the rear of my car is covered with oil, as smoke is coming from the oil on the exhaust, so I look under the car and sure enough, from the diff back there is oil everywhere. So I call for a rollback to come tow it up to to the Honda dealership. I am thinking I will probably have warrany trouble with the mods on the car, what do you think? Mods are listed below.

 

The VAFC and clutch kit might be your downfall. The rest may simply be used as an excuse to pigeon hole you into the catagory of "car abuse".
Take heed of what Hecash just said.

 

Dealership called today, and said it looks like something hit the diff housing and caused it to crack, and that the whole unit is basically useless. I haven't been by to check it out yet and see for myself, although they said (obviously) warranty won't pay for it. Hopefully my insurance will take care of most of it, haven't called them yet. They quoted $4300 for labor+parts.

 

You should see if someone on the board has a spare they'll sell you. A few guys have gone to aftermarket diffs and has the stock one laying around. Put up a post in the WTB section.

 

I doubt something came up and hit the diff housing hard enough to break it. More likely the internals let go, and some teeth got wedged between the crownwheel/pinion and broke the casing. If you have a warranty I would put it back on them.

Speedracer.

 

I seem to recall someone posting about their cracked diff housing within the last few months. The crack was a longitudinal one from where to the prop shaft goes into the diff and proceding to the main body of the diff. Sorry, I can't find that thread. It had a few really nice photos in it. There was quite a bit posted on how it might have happened.

 

http://forums.s2ki.com/forums/showthread.p...threadid=194758

 

My rear had a nice little while. A tooth of the pinion gear broke off and shot into the case causing this...

$4300

you are better off having your rear done with better gears and the comptech unit. it will be cheaper...

 

When they said "something" hit your diff casing, were they stipulating that something hit it from the outside or something broke loose and hit it from the inside?
I now see that you live near where Rick (Rick's Accessories) lives. When Rick first started this rear gear thing, I had a telephone conversation with the first guy he got to do these gear swaps. I think Keith was his name. He indicated to me that many of the rear diffs he did the swap in showed signs of unusual outer pinion bearing wear. Some of them were even on the verge of possible failure. You might want to try and contact Rick to find out where this Keith fellow is now. (I think he moved to the central U.S.) He might give you a more first hand explanation than what I'm giving you here.
Should this bearing fail (and I can't give you specific reasons why it would as there can be many), there would be tremendous movement in the pinion shaft/gear. This could cause a tooth to break off and send it into moving parts that could exert explosive forces into the casing. I'm not saying that yours is this scenario but it is worth some thought.

 

now this is making me worry....