I know shavings and "sludge" are normal in the diff fluid, but at what point do chunks come into play? I changed the fluid in my 130k AP2 about 2 weeks ago and found 6 decent sized chunks and got a "new" ap2 diff. Owner didn't change the fluid in the "new" one which has 80k on it and I just changed it and found 3 chunks about the same size as the ones I found in mine. Is it coincidence both of these diffs are toast or can this be considered normal after this mileage? With the car off the ground I was getting a bit of lock on my diff when I held one wheel and turned the other. The new diff I put it was very smooth, I could hold one side and easy turn the other by hand. No whine from either and the only thing that clued me into possible issues is the chunks on the drain plug.

 

Yea from the looks of those chunks, its toasted.

 

Chunks are never good, or normal.

 

Don't be so quick to call the dif toast.

Are the chunks D shaped?

 

Similar thread if they are D shaped : https://www.s2ki.com/s2000/topic/515...chunk-in-diff/

 

Its not one of the friction plate ears, I'm guessing its from a tooth somewhere. I think regardless I'm going to make rebuilding my original my winter project.

I'm cracking it open today and we'll see what she looks like.

 

Sometimes a piece of pinion tooth will break off as this is what it looks like. It will be ok as it is off the end of a tooth where the gear makes no contact.

Good luck, hope this is all it is

 

Thanks Puddy, I thought it was weird that this is the second diff I've seen this in, but haven't seen seen anyone else find similar pieces. Going to attempt a rebuild myself, but if my past mechanical undertakings are any indication I'll probably be sending it to you before too long.

 

Sounds good and good luck, you can PM or call for help if you need it.