Join Date: Dec 2008
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Ultimate Front Diff Thread
Ok, so after hours of searching only to find others with the same problem and no solutions, I dug deeper into my front diff. I'll post what I've learned. If there is a mistake, please correct me. If there is other info, please add it.
I already blown up the stock plastic cage and replaced it with billet aluminum part. I was still having AWD engage while in 2WD. I completely unplugged the AWD at the front diff. It still locked into AWD. Cluncked REALLY hard too.
I pulled it apart to really understand how it worked. I leared that when the switch is activated and the coil is magnetized, it pulls the armature plate agianst the cover plate causing friction between the armature plate and the cover plate. Because the armature plate "slows" with the friction between the two, the ring gear rotates around the cage and causes the roler bearings to push inward and lock agianst the output hubs. This ultimately turns the front wheels.
Now because I already rebuilt mine with new parts and I was still having problems in the 2WD mode, I tore it all apart again. I found two problems that are cuasing what you may have experienced:
FIRST: the H-springs were damaged and did not push outward on the bearings in the factory cage. This would intermitantly allow the bearings to "fall" inward and the ring gear rotate into the AWD position. Its just plain physics. IT IS NECESSARY TO REPLACE THE H-SPRINGS WHEN REBUILDING.
SECOND: the grove on the inside of the billet cage has a tolerance that is too tight. This is where the h-spring rests. When the bearing is pushed in by the ring gear, it smashes the h-springs into a grove. The aluminum is so tight that the springs cannot retun and push the bearing back out. This allows the bearigs to again "fall" inward, causing the ring gear to rotate and act like its in intermittant AWD.
Tommorrow, I'm contacting the manufacturer of the cage and see what they can do. I'll post details later, but as I feel they can fix this, I won't flame the company...yet.
I'll post picture of the springs jammed into the groove that has been cut for them. Its obvious when compared to the stock cage how tight the billet cage is.
PHOTO CONTEST - Ugliest plastic cage???
Notice in the 3rd photo of the plastic piece sitting to the billet cage, this is how the spring should look. Its not smashed into the caged (Granted there is nothing left)
Last edited by cheeeto; February 27th, 2009 at 07:08 PM.
Reason: add photos