3-wheel drive...?

[Team Japan]

First off, hi to everyone. My first time on here, it was reccomended by Roughtrax. Looks lke a good site!

I have a '93 Surf in burgandy with the 3.0 diesel, auto, 2-inch lift and 16-inch wheels.

Now the problem: I was out green laning on Saturday, when I gave it a bit of stick in low range, trying to back out of The Ditch Of Mortality. Suddenly there was a metallic bang from the front, followed by several more every time I went near the throttle. The front right wheel was twitching instead of turning.

Most likely theory is that the splines on the driveshaft or diff have stripped and the banging is when it jumps round a notch.

Just thought I'd see if this is a common problem, or if anyone else has had the same happen? We'll have to take it apart anyway to see what has really happened in there, but it might be good to know if there's a common component to check first.

Cheers for any advice,

Andy

[POPEYE]

If the 2" lift is on the suspension it's likely you've buggered the CV joint or the shaft, for off road with any sort of sus lift it's best to use diff drop spacers, this lessens the angle of the front drive shafts gained by the lift, also free wheeling hubs for when you dont need 4wd helps wear on the cv boots, so it is a common prob with sus lifts,
and welcome!!!

[TonyN]

Like Popeye said, CV's first, they are the weakest part normally, then the diff gears themselves.

Welcome along.

[Team Japan]

Thanks guys. We'll get it apart this weekend and have a look anyway, but now I know to start with the CVs. I'll let you know what I find - let's just hope it's not the diff!

Cheers

Andy

[POPEYE]

i have the drawing for the spacers if your handy with a drill and file, let me know if you want it and i'll stick it on, only prob you might find fitting them is the diff wont drop enough cos it hits the exhaust crossover bit, useually ok on a pukka toyota exhaust but found problems with an aftermarket one,
some have cut and rewelded some have given the pipe a good seeing to with an ammer

[Growler]

i have the drawing for the spacers if your handy with a drill and file, let me know if you want it and i'll stick it on, only prob you might find fitting them is the diff wont drop enough cos it hits the exhaust crossover bit, useually ok on a pukka toyota exhaust but found problems with an aftermarket one,
some have cut and rewelded some have given the pipe a good seeing to with an ammer

Sounds like my kind of fix

[Team Japan]

Cool, thanks Popeye. I'll have a look and see what caused it first, I'm reluctant to lower the diff if I don't have to, since it would defeat the ground clearence gained by the lift kit. If it looks like it was the cause though, and might be a recurring problem, I'll certainly take a look at the drawings. I'll let you know, thanks.

Cheers

Andy

[POPEYE]

Here's the drawing in case, you dont loose too much ground clearance but it does take the acute driveshaft angle down a bit, i never fitted these but i dont do "off road" so not a big issue, (although i'm surpossed to be doing some laneing up the farm where my son gamekeeps)

[Team Japan]

Excellent, thanks very much.

This is the ditch which caused it, by the way. The pics are from a previous trip when I did make it through in one piece!









Cheers,

Andy

[qcampbelloffroad]

Diff problems

Looks like the front diff may be the problem. Knocked a few teeth off the crown wheel and possibly the pinion shaft as well.
If you try engaging 4WD on level ground and feel a snatch in the drive train as you move along, basically the system winds up (as usual) until it reaches the missing teeth and can release the wind up or jump over the missing teeth.
QC

[Team Japan]

Looks like the front diff may be the problem...

It's starting to look like you might be right there, QC. I couldn't make it to the workshop this weekend due to family issues, but my mates very kindly set about my vehicle for me.

They said the shafts and CVs all looked fine, and so had got as far as tracing the problem to somewhere inside the diff. (They also said they were never going to work on a Toyota ever again!)

So, the next step is to take the diff apart and see what's inside, but either way, I was wondering whether the easiest option is a whole second-hand diff, rather than trying to swap parts around. If so, does anyone know where I can get one?

Cheers

Andy

[stormforce]

easiet way is to swap the diff over rather than p155 about stripping it down.I have just sold the 3.0 diff i got but if i get another i'll let you know.We'll also need the diff codes aswell

[qcampbelloffroad]

I would agree with Storm Force. Your going to have to take the diff off the car to get the front cover off to verify stripped teeth. Rather than strip all the internals out to change the ring gear and pinion shaft, just put the replacement unit straight in.
Regardless of VIN plate coding I would take the cover off both your diff and the replacement to confirm you are changing like with like before you bolt the new one in.
QC

[Team Japan]

Thanks for your advice, guys.

We wanted to take my diff apart at least far enough to be sure that it was definately the problem - this is what we found:



Hmm... yep, it's definately the problem!

I agree with you guys though, there's no point going any further with this diff or trying to swap parts if I can just get a whole unit to bolt back up to the car.

Stormforce, we couldn't find any codes, any idea where to look for them please? The only writing on the casing we could find was "ADD. OIL TYPE GL-5 75-90", which I assume is just telling me what sort of oil to add. Or is "ADD." the code? Are the 3.0 diffs not all interchangeable, if I get one form the same year?

Also, if you don't mind me asking, how much did your one sell for, just so I have an idea of the going rate?

Cheers

Andy

[Albannach]

ADD = Automatic(ally) Disconnecting Differential