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Discussion Starter #1
I just had my front diff. fluid changed- and got a very nasty surprise. This bolt was found in my front housing- along with a sh** ton of shavings.
I had a front locker and RCV axle shafts installed a few months ago. Haven't used the locker much until a couple of weeks ago. At that point the Tcase started making noise. My JK only has 20K miles- but I decided to get the fluid done early. They checked the diffs for me in the process- and they found the bolt.
I know a certain of amount of shavings is normal- I checked the fluid myself recently and found very little. We did do our own gear install about a year ago so I am super-paranoid and check it often. But the goop they were pulling out is NOT normal. Yes, it was Jiffy Lube- but they made a point to show me the fluid as it was draining and the chunks in it. No question there.
We need to get in there and take an in-depth look (not leaving that to JLube). Anyone recognize where this could have come from? So I can know where to look? Looks like possibly a bolt from the Yukon locker casing but my installer says its nearly impossible for one to work its way into the front diff. even if it comes loose.
I don't want to point fingers (Yukon, installer, RCVs, gears etc.)- I don't have time. I am supposed to leave for Lake Tahoe and Rubicon trail this freaking weekend. Non-refundable house already rented. I just want to get in there and get it fixed. The installer on the locker won't be available this weekend.
 

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Googled yukon locker diagrams. Looks like it could be from there. Maybe the cone plate on the top. Could be a fluke, or it could be the locker is going to come apart. For peace of mind, get in the diff and spin the locker around and check all the bolts. It will be tight, but you need to do it.
 

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I just had my front diff. fluid changed- and got a very nasty surprise. This bolt was found in my front housing- along with a sh** ton of shavings.
I had a front locker and RCV axle shafts installed a few months ago. Haven't used the locker much until a couple of weeks ago. At that point the Tcase started making noise. My JK only has 20K miles- but I decided to get the fluid done early. They checked the diffs for me in the process- and they found the bolt.
I know a certain of amount of shavings is normal- I checked the fluid myself recently and found very little. We did do our own gear install about a year ago so I am super-paranoid and check it often. But the goop they were pulling out is NOT normal. Yes, it was Jiffy Lube- but they made a point to show me the fluid as it was draining and the chunks in it. No question there.
We need to get in there and take an in-depth look (not leaving that to JLube). Anyone recognize where this could have come from? So I can know where to look? Looks like possibly a bolt from the Yukon locker casing but my installer says its nearly impossible for one to work its way into the front diff. even if it comes loose.I don't want to point fingers (Yukon, installer, RCVs, gears etc.)- I don't have time. I am supposed to leave for Lake Tahoe and Rubicon trail this freaking weekend. Non-refundable house already rented. I just want to get in there and get it fixed. The installer on the locker won't be available this weekend.
where else is it going to go?
 

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Googled yukon locker diagrams. Looks like it could be from there. Maybe the cone plate on the top. Could be a fluke, or it could be the locker is going to come apart. For peace of mind, get in the diff and spin the locker around and check all the bolts. It will be tight, but you need to do it.
x2. If you have a lot of shavings dont wait on this one. It looks like it's been bouncing around a while.
 

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Discussion Starter #5
We're definitely not waiting- you're right. Opening it up tomorrow but trying to figure out what it could be in advance. This bolt isn't damaged enough to be the cause of the shavings - wondering if another bolt is already obliterated in there. Or my gears are shot. I will say the noise we heard is gone- and there is no discernible gear whine or anything else at this point. But I haven't driven it more than 5 miles.
Sent an email to Yukon but not hopeful for response right away. Of course it could very much be something else- but can't think of what else it could be.
 

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is it a zip locker? thats one of the 8 or so bolts that holds the 2 sides of the case together. the little tab is SUPPOSED to keep it from backing out.
 

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If this was ME, in your situation, I would jack up the axle, pull the diff cover, clean and dry the hell out of everything, give everything a thorough inspection, and if all else looked good, put some locktite on a new bolt, then screw it in along with the locking tab, then torque it down,
replace cover and new lube. And then go wheel the hell out of it!!!!
If it doesn't look good upon inspection; then I would have to weigh the difference.......Lost rent money vs blown diff!!!!!
Best of luck to you on whatever decision you make!!!!
 

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Discussion Starter #8
Yes- its a zip. And to me it does look like those bolts. Left a vmail and sent an email to Yukon to try and find out for sure. My locker installer says they generally don't respond to "the public" so who knows.
I don't disagree with you Don- are you my installer? Cuz that's what he said. LOL. I just don't want to use Rubicon as my test trail. My AAA doesn't go that far. But yeah- if my diff. or gears look remotely mangled it's not going anywhere.
 

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Discussion Starter #10
Ewwwwe!! Hope everything's ok :(
Me too KJeep.
Really frustrating considering I probably checked that fluid a month or two ago- which was probably less than 1000 miles ago.
The ONLY good thing to come from this is at least nothing blew up on Rubicon. 8 hours away. I keep telling myself that as my rental house and $1000 slip from view.....
 

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pop the cover and you will know in 5 minutes if the gears look good or not. If gears look good you can always just pull the locker for the trip.
 

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Discussion Starter #12
So I talked to Yukon and there were as helpful as can be for the moment. They use 12 pt. bolts- the one that came out of the diff is a Hex head. BUT they agree that its suspicious- it is exactly the same size (M6) and length as what they use on the case. They're UPS red-ing me some 12 pts.
We'll see tomorrow. As mentioned it should be fairly easy to spot- and I am fairly confident I am going to find a missing bolt on the locker. I can do without a locker....its the gears (and the metal shavings) that worry me.
Crossing fingers toes and eyeballs.
 

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pop the cover and you will know in 5 minutes if the gears look good or not. If gears look good you can always just pull the locker for the trip.
it probably wouldnt drive very well without a carrier
 

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Wow!
 

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You are into this one now. Spin the ring gear and make sure there's no damage there. You will need to get a look at the pinon teeth, too. If you cannot got a view with a spot mirror then you'll have to pull the carrier to get a look at it.

Sorry bud, no way I'd wheel this one until it was 100% checked out and repaired.

Bob K.
 

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Discussion Starter #17
I neglected to mention above that Yukon sent Hex head bolts- so clearly at some point they changed from 12 pts. to Hex type. The gears look surprisingly good- the brownish part you see in the pic above is just an odd reflection. Cleaned everything out of the carrier- you could practically eat off it. Ok- exaggeration. Re-did ALL bolts with lock tight- which was clearly missed by Yukon to start. Its back together so at least its driveable in 2WD. This coming week we'll see how Yukon backs their stuff. Needless to say I want a new locker.
 

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Good news! Yukon has a big presence up with with Randy's Ring and Pinion. They seem like a great outfit. Hopefully they will do right by you.


Bob K.
 

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Discussion Starter #19
The good news is short lived. Airline to the locker case must have gotten mangled. Locker will not engage- blow by. So my weeklong trip to LakeTahoe to run Rubicon is a waste. Not running Rubicon without a front locker. Been planning this trip for months and spent a ton of money on an over-priced rental. Not to mention lost wheeling time with good friends. Thank you Yukon.
 

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Take a quick breath. You know the extent of the damage. If the gears are fine, button that thing up and go on the trip. The front locker OOS is not a trip breaker. Not to me. You can still have a great trip. Deal with the locker when you get back.
 
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