Holy Crap have you seen this Failure Before? - Camaro5 Chevy Camaro Forum / Camaro ZL1, SS and V6 Forums

ABM2SS · 10-13-2021, 06:36 AM

Recently replaced my Differential with one out of a 43,000 mile 45th Anniversary SS M6 due to a broken Ring Gear. After 300 miles, during a moderately hard acceleration I heard/felt a BANG followed by bad driveline vibration. Had it towed home and found this.
Has anyone seen the rear mount on the Differential fail before?
The Differential came out of a front-end total. All I can imagine is that the mount was somehow damaged in that collision.

gtstorey · 10-13-2021, 08:37 AM

Is the diff cover bushing stock? It looks to me like it might have been replaced. Someone might have gotten carried away when they cut a stock one out. Someone posted in the last few months that had a large piece missing similar to yours but it appeared to have been cut out and had red aftermarket bushings. They may have been missing a piece from the bottom though.

I guess it's possible a front end collision pushed the driveshaft backward and in turn pushed the diff in such a way to crack the ring around the bushing, but I would have expected it to likely ruin the diff or pinion bearings if it hit that hard.

ABM2SS · 10-13-2021, 08:57 AM

Quote:

Is the diff cover bushing stock?

When I get everything apart I'll compare the bushing to my original. I plan to use the Cover off the old one. Hope everything is alright inside. I paid $1300 for that used Differential.

btwwat92 · 10-13-2021, 10:03 AM

Quote:

Originally Posted by gtstorey

Is the diff cover bushing stock? It looks to me like it might have been replaced. Someone might have gotten carried away when they cut a stock one out. Someone posted in the last few months that had a large piece missing similar to yours but it appeared to have been cut out and had red aftermarket bushings. They may have been missing a piece from the bottom though.

I guess it's possible a front end collision pushed the driveshaft backward and in turn pushed the diff in such a way to crack the ring around the bushing, but I would have expected it to likely ruin the diff or pinion bearings if it hit that hard.

That was me that posted a few months ago. I still have no idea how it happened or when. I just know that when I went to pull the diff for a gear swap, I found it that way.

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AlanRubin · 10-13-2021, 12:33 PM

If someone cut out the old bushing to put a new one in, they could have gone
too deep with the cuts and weakened the ear. From that angle, can't tell if it
was sheered off, or cut. IF sheared off, the surfaces will be pitted and jagged.
If it was cut, it would be a flat consistent textured surface. The damage to the
isolator is because the pinion angle was way off.

ABM2SS · 10-19-2021, 06:55 AM

Looks like the used Differential was damaged. Must have been cracked before I installed it. The bushing was an original. Once I replace the bushings and swap on my old rear cover I'll start putting it back together again.

gtstorey · 10-19-2021, 08:25 AM

Hopefully someone dropped it off a fork lift and that it wasn't damaged in the front end collision. That would take a lot of force if transmitted through the driveshaft and into the pinion.

ABM2SS · 10-19-2021, 11:05 AM

Quote:

Hopefully someone dropped it off a fork lift and that it wasn't damaged in the front end collision. That would take a lot of force if transmitted through the driveshaft and into the pinion.

My thoughts exactly. But I spent $1300 on the used Differential, so I feel obligated to put it all back together and take that chance.

ABM2SS · 10-20-2021, 08:17 AM

Anyone have a good method for removing the Differential Bushings without damaging the Housing? The BMR instructions are to use a 2" hole saw on the rubber (which I did) then use a screwdriver to pry the sleeve out. I practiced prying one out on the old Differential and in the process did some serious damage...

gtstorey · 10-20-2021, 09:26 AM

I cut mine with a demo saw, but you have to be very careful to not get into the aluminum.

CamaroCracka · 10-20-2021, 11:55 AM

I used a reciprocating saw with a short metal blade. I did not cut completely through the material or at least I thought I wasn't, and then used a chisel to fold the metal housing of the busing in on itself. When it was done there were a few nicks, but nothing serious.

ABM2SS · 10-20-2021, 12:17 PM

Quote:

I used a reciprocating saw with a short metal blade. I did not cut completely through the material or at least I thought I wasn't, and then used a chisel to fold the metal housing of the busing in on itself. When it was done there were a few nicks, but nothing serious.

Thanks. I'll try that on my other "practice" Bushing in the old differential tonight.

I also considered heating-up the area with a propane torch since aluminum expands more than steel when heated. Just afraid of heat traveling and over-heating the axle seals and bearings.

gtstorey · 10-20-2021, 01:04 PM

I think I tried heat when I did it before I used a saw and didn't have any luck.

ABM2SS · 10-20-2021, 01:12 PM

Quote:

I think I tried heat when I did it before I used a saw and didn't have any luck.

OK, thanks I'll skip the torch.

10-13-2021, 06:36 AM	#1
ABM2SS Drives: 2010 SS M6 ABM Join Date: Mar 2015 Location: Nashville, IN Posts: 280	Holy Crap have you seen this Failure Before? Recently replaced my Differential with one out of a 43,000 mile 45th Anniversary SS M6 due to a broken Ring Gear. After 300 miles, during a moderately hard acceleration I heard/felt a BANG followed by bad driveline vibration. Had it towed home and found this. Has anyone seen the rear mount on the Differential fail before? The Differential came out of a front-end total. All I can imagine is that the mount was somehow damaged in that collision. Attached Images Last edited by ABM2SS; 10-13-2021 at 08:13 AM.

10-19-2021, 06:55 AM	#6
ABM2SS Drives: 2010 SS M6 ABM Join Date: Mar 2015 Location: Nashville, IN Posts: 280	Looks like the used Differential was damaged. Must have been cracked before I installed it. The bushing was an original. Once I replace the bushings and swap on my old rear cover I'll start putting it back together again. Attached Images

10-20-2021, 08:17 AM	#9
ABM2SS Drives: 2010 SS M6 ABM Join Date: Mar 2015 Location: Nashville, IN Posts: 280	Anyone have a good method for removing the Differential Bushings without damaging the Housing? The BMR instructions are to use a 2" hole saw on the rubber (which I did) then use a screwdriver to pry the sleeve out. I practiced prying one out on the old Differential and in the process did some serious damage... Attached Images

10-20-2021, 11:55 AM	#11
CamaroCracka Drives: 2010 Turbo LS3 Join Date: Dec 2009 Location: Palm Bay, FL Posts: 2,782	I used a reciprocating saw with a short metal blade. I did not cut completely through the material or at least I thought I wasn't, and then used a chisel to fold the metal housing of the busing in on itself. When it was done there were a few nicks, but nothing serious. __________________ 2010 SS - On3 kit with downpipe cutout, CTR 78/80, CompCam 239/251 620/632 122+4, E85, Z28 suspension and ZL1 diff with Outlaw axles. Gen6 ZL1/1LE brakes. 2011 Vert - 416/w 230/236 .612/.602 115lsa, 1LE suspension w/32mm rear bar. Z28 diff. ZL1 brakes.

10-13-2021, 08:37 AM	#2
gtstorey Drives: 2010 Camaro SS2,L99, LSA SC Join Date: Aug 2017 Location: Huntsville, AL Posts: 2,185	Is the diff cover bushing stock? It looks to me like it might have been replaced. Someone might have gotten carried away when they cut a stock one out. Someone posted in the last few months that had a large piece missing similar to yours but it appeared to have been cut out and had red aftermarket bushings. They may have been missing a piece from the bottom though. I guess it's possible a front end collision pushed the driveshaft backward and in turn pushed the diff in such a way to crack the ring around the bushing, but I would have expected it to likely ruin the diff or pinion bearings if it hit that hard.

10-13-2021, 12:33 PM	#5
AlanRubin Banned Drives: 2010 LS Join Date: Feb 2021 Location: Pgh Posts: 411	If someone cut out the old bushing to put a new one in, they could have gone too deep with the cuts and weakened the ear. From that angle, can't tell if it was sheered off, or cut. IF sheared off, the surfaces will be pitted and jagged. If it was cut, it would be a flat consistent textured surface. The damage to the isolator is because the pinion angle was way off.

10-19-2021, 08:25 AM	#7
gtstorey Drives: 2010 Camaro SS2,L99, LSA SC Join Date: Aug 2017 Location: Huntsville, AL Posts: 2,185	Hopefully someone dropped it off a fork lift and that it wasn't damaged in the front end collision. That would take a lot of force if transmitted through the driveshaft and into the pinion.

10-20-2021, 09:26 AM	#10
gtstorey Drives: 2010 Camaro SS2,L99, LSA SC Join Date: Aug 2017 Location: Huntsville, AL Posts: 2,185	I cut mine with a demo saw, but you have to be very careful to not get into the aluminum.

10-20-2021, 01:04 PM	#13
gtstorey Drives: 2010 Camaro SS2,L99, LSA SC Join Date: Aug 2017 Location: Huntsville, AL Posts: 2,185	I think I tried heat when I did it before I used a saw and didn't have any luck.