Front Differential Catastrophic Failure

DiscoHasBeen

Well-known member
Aug 7, 2016
1,171
262
Indy
I had something similar happen to my Wrangler. The inner bearings failed, which allowed some of the components to shift, which led to broken teeth and all kinds of other s***. Anyway, I replaced everything. It being a Jeep parts were cheap and readily available online. My brother-in-law is a nut about Jeeps so he knew a guy that was willing to do the work for me. Pulled the dif, loaded it in the truck, loaded up all the parts, took it to his house. A couple of weeks later picked it up, stuck it back in the Jeep, all was well.

If you have another set of wheels take the time and do it right, that's my opinion. Especially since you say you're keeping the rig. Why take the chance on having the F with it again later down the road.
 

Blue

Well-known member
Mar 26, 2004
10,043
856
AZ
That isn't a slope that I'd worry about at all. Proper jack stands, engaged parking brake, chocked rear wheels, you're fine. But I'd push it into the garage anyway to have some shade and privacy and security so you can leave all the pieces and tools scattered about. We could probably push it in with a couple floor jacks under the front axle. I can bring one over and I'm sure Fitz has one too!
 
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donniefitz2

Well-known member
Sep 15, 2020
138
56
Scottsdale, AZ
fitzventure.com
That isn't a slope that I'd worry about at all. Proper jack stands, engaged parking brake, chocked rear wheels, you're fine. But I'd push it into the garage anyway to have some shade and privacy and security so you can leave all the pieces and tools scattered about. We could probably push it in with a couple floor jacks under the front axle. I can bring one over and I'm sure Fitz has one too!
Yep. No need to even have the tools spread out for long (the driveway is fine). If you buy that complete axle, we'll have it mounted in like 2...maybe 3 hours, max.

This is really not a big deal at all. It would take twice as long to read this 3 page forum thread than it will to replace that axle in the driveway with a Crescent Wrench and a pry bar.

I have the tools and the will to win. When you get back in town, we'll make it happen. I might make YouTube a video out of it if you're down with that.
 

ArizonaBasc

Active member
Jun 21, 2020
25
3
Phoenix, Arizona
Hey everyone sorry to dig up an old thread but I have an update. I finally got the time to commit to the job and purchased that axle that I linked to. However, I don't think that the part is even usable. There is bad rust over the whole assembly, especially the shock tower mounts which is what I am most worried about. I bought it from a pretty big eBay seller LKQonline which included $150 that I may not get back if I try and return it. What do you all think I should do? I haven't had to deal with something like this before, I am a lot younger than the average Disco owner.axle1.jpgAxle2.jpgAxle3.jpg
 

p m

Administrator
Staff member
Apr 19, 2004
15,617
838
58
La Jolla, CA
www.3rj.org
OMFG... what a pile of junk.
I guess you can wire-wheel the rust off it and weld up a few badly-rusted pieces, but... it is still a pile of junk.
 

ArizonaBasc

Active member
Jun 21, 2020
25
3
Phoenix, Arizona
Wow ok I just had to look up what a third member is but that sounds so much simpler than what I was going to attempt to do, I will just do that with the internals of the "new" part. do I even need to drop the axle on the car for that right now? Thanks to everyone for the input, if this isn't the case and I need to use the rusty one ill try and find a shop to weld new mounts...

PS if you are going to the Phoenix AZLRO meeting this Thursday ill see you there!
 

rovercanus

Well-known member
Apr 24, 2004
9,643
244
Jack up truck. Remove wheels, remove calipers and rotors, remove 4 bolts each side for the hubs, pull hubs out about 6 inches. This will pull the axles out of the third member. It would be helpful if you can support them or pull them all the way out so you don't mess up the axle seal.
Drop your drive shaft and remove all the bolts for the third member and wiggle it out. It's heavy, don't smash a finger. Use RTV of some sort as a gasket since this is what the factory used.
Assembly is the reverse.
 
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ukoffroad

Well-known member
Jan 13, 2010
2,125
168
Lynchburg, Va
Jack up truck. Remove wheels, remove calipers and rotors, remove 4 bolts each side for the hubs, pull hubs out about 6 inches. This will pull the axles out of the third member. It would be helpful if you can support them or pull them all the way out so you don't mess up the axle seal.
Drop your drive shaft and remove all the bolts for the third member and wiggle it out. It's heavy, don't smash a finger. Use RTV of some sort as a gasket since this is what the factory used.
Assembly is the reverse.
Exactly. Heavy but manageable. Be sure to use a magnet to get out any little pieces in the housing before reassembly. That new axle is a hot mess.
 
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CBiDrive

Well-known member
Sep 20, 2007
108
22
Parker, CO
I had a blast reading this thread, as I went through all this two D1's ago. Start with basics. Since you have it out, disassemble and clean (plus you learn how it all goes together). I did this in my driveway in a couple hours. I am willing to bet you just need a new third and new CV or universal (I've never done a D2 axle so not sure). Tillery or Fleabay are your best bets on affordable OEM replacements. Buy shares in Rustoleum and go play.