Blown Front Diff - Again After 110K

Discussion in 'Volvo Forum' started by Espey127, Oct 26, 2022.

  1. Espey127

    Espey127 Bobtail Member

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    Dec 13, 2016
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    2019 Volvo VNL760

    At 402k (52k out of warranty), noticed a minor leak from the front diff. After inspection at dealership, they found small traces of metal which lead to replacement. My question at the time was why this occurred, never got a straight answer. What assurances might I have that it wouldn't happen again in 200k (was off my 90k).

    Now, 110k later, not only is it blown again but the axles are twisted as well. First they stated that it's a lack of lube. Can't be, 3 days prior left dealership for servicing and 22 point inspection, there wasn't any leakage reported. Now they say shock load, of course warranty will not cover it.

    When the first one blew, there was an event where the diff felt like it was jumping (from car days, felt like a Positraction when making turns on wet road), lifted from throttle straight away. And a similar event occurred recently as well, again lifting from throttle quickly.

    What causes shock load?
    Why is diff jumping around?
    Is there anything I can do besides bend over?
     

    Attached Files:

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  3. AModelCat

    AModelCat Road Train Member

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    That chunk missing from the ring gear, that wasn't shock load IMO.

    When the fracture is smooth like that, its been fracturing gradually over time until it just gets too thin and breaks off.

    When a fracture is jagged and aggressive in appearance, that's a shock fracture.

    Twisted axles, hard to say. Aggressive acceleration? Maybe the busted tooth worked its way into the spider gears and jammed them up, then when you turned it torqued up the axles.

    Why's the oil residue look like mud?
     
  4. Flint1

    Flint1 Heavy Load Member

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    I'd say it was very hot..
    Side bearings are melted right out of it.
    Axle shafts almost look like the were red at one point in the side bearing area.
    Once the play in the side bearings developed the gear probably started loading near the tip of the tooth.
     
    Last edited: Oct 26, 2022
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  5. W923

    W923 Medium Load Member

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    Was it a DuPont overhauled salvage yard diff.
    As some of the other responses have addressed the oil must have looked like #### and things look like they might have been hot.
    Do you know what the differential nest looks like. Possibly had some kind of seizure in there causing the posi feeling and the twisted axle shafts. Seems like the axle shaft would have had to be hot to twist like that and not brake but I guess melting the carrier bearings would do that. As far as the broken gear tooth it does look like it was a long time in the making.
    I would be making some phone calls about where that power divider came from
     
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  6. Espey127

    Espey127 Bobtail Member

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    They divider was brand new from Valley Truck. Installed by Volvo dealership.

    Haven't seen the oil, good question. The smooth fracture is a solid point.

    The question becomes...what are my options? Seems like I'm getting stiffed no matter what.

    It's already going into second week. First week was fighting over warranty between Volvo dealership installing it, Valley Truck and now a different Volvo dealership unit is currently at. The current shop doesn't deal with any warranty they didn’t install themselves.
     
    Last edited: Oct 27, 2022
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  7. skallagrime

    skallagrime Road Train Member

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    Sorry about your luck op, just wanted to say i can smell the pictures through the internet and i dont like it
     
  8. kranky1

    kranky1 Road Train Member

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    It did, look where the contact patch is on the teeth. I’d almost say the pinion depth may have been wrong when that was put together. Little wonder it broke one off. Looks like the gear oil is coked onto the housing, that thing was volcanic. Should have been able to smell that from across a parking lot.
     
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  9. Espey127

    Espey127 Bobtail Member

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    Lastest update...so it can get even worse after next inspect. Already paid 2.2k for first level of advanced diag and towing.

    INSPECT HUB BEARINGS FOR DAMAGE AND CLEAN OUT DEBRIS
    Labor: $1,020.50

    CLEAN AXLE HOUSING AND INSTALL REMAN DIFFERENTIAL
    Labor: $1,570.00

    Labor: $2,590.50
    Parts: $4,246.18
    Shop Supplies: $200.00
    Taxes: $422.20
    Total: $7,458.8
     
  10. rolls canardly

    rolls canardly Road Train Member

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    Does this guarantee they actually physically checked your fluid level, NO.
    So many times people count on techs to be competent and diligent.
    Not all are. The guys that keep having "come-backs" aren't around long.
    Looks like it was bone dry and deep fried.
    Is it a stinky, smelly mess?
    No, (or low,) Oil is at least a contributing factor.
     
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  11. Cattleman84

    Cattleman84 Road Train Member

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    That looks like it got hot as ####. Oil residue looks burnt, axle shows evidence of extreme heat.

    No leaks doesnt mean its has proper lubrication... Id say it was very low on gear lube... For a very long time.
     
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