“Honey, I think the car is making a noise…”

Post by **- Pete -** » 07 Jan 2022, 17:06

IMG_3760.MOV: If the video doesn’t play, let me know.; (41 MiB) Downloaded 119 times

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Free bevel gear if anyone needs some parts!

Post by **abscate** » 07 Jan 2022, 18:20

What happened to the bevel gear oil?

Post by **- Pete -** » 07 Jan 2022, 18:26

It let itself out.

Hard to determine the order of events with this one, but the oil became repurposed once the case was deconstructed. Right now I believe the gear oil has melted through snow & ice & is holding gravel & dust together in little clumps

Post by **Blacklab467** » 07 Jan 2022, 20:31

Wow, looks like the pinion bearing seized and made clearance elsewhere! Do you have a spare BG?

Post by **MoVolvos** » 07 Jan 2022, 23:18

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That's been dry for sometime?

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Post by **- Pete -** » 08 Jan 2022, 00:25

Actually, no, Ben. It’s been leaking for some time, but it wasn’t empty. A small gear oil leak looks far worse than it usually is. I’d lent the car to some of my family over Christmas/New Years & just prior to that I went through everything on it & did check the gear oil level. Pulled the plug & it was right up to the bottom of the hole. Now, that was 3 weeks ago. Could it have developed a rapid leak? I suppose so. All I know is that it developed an extremely rapid leak when the case called it quits!

I can see that one of the bearing races cracked, so I think that it was more along the lines of a bearing failure -> race expands -> output bore where bearing lives gives way. Obviously the ring & pinion took a beating once the case lost its integrity. Once everything started flopping around, the front CV joint on the driveshaft threw up the white flag so that needed to be replaced too. Pretty sure that one was still original. Surprising the boot has held up for 311,000 miles. I don’t recall replacing it, ‘tis possible though with my memory. The originals are usually light gray in color & this one was very much so.

Guess I can’t do my welded collar sleeve setup I was SO looking forward to. Not with this BG anyway.

Cars back together now. I had a new CV joint (thanks to Colorado Driveshaft), a good spaRe BG & new collar sleeve service kit all on hand so made quick use of all those bits.

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Amazingly, the original collar sleeve DIDN’T give way! Rrreally surprising to see this.

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Post by **MoVolvos** » 08 Jan 2022, 00:55

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Hi Pete, you can see it a lot better but it's hard to tell from the pictures whether the case had been cracked for sometime from the oil stains. Could have just been seeping through the cracks then leaking out fast in one area. As things started to heat up with no oil it just exploded in the end.

It still gotta be cold even having a garage while working under the car in winter. Currently have to borrow my friends driveway as it's south facing so when the sun is out it blunts the cold even better than being inside the garage with the door closed.

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Post by **- Pete -** » 08 Jan 2022, 01:22

Well, it wasn’t fully “exploded”. I helped it a little bit.

It was -25ish yesterday morning when death came for this BG. No warnings, no odd noises like you’d expect from an empty transfer case. It all happened in about 4 seconds. The car felt lethargic, kept slowing despite constant go-pedal pressure. Clunk, bang, crack, grossness-Maximus et.al clattering de-bõn-qüee-quēę. Wet t-case & the smell of stinky stiff burning off of the downpipe. When I brought it into the shop this morning, that’s when I head a loud CRACK. I assume that’s when the case busted.

If you can see the video atop the first post, you will see what the case looked like prior to me “helping” it.

It’s a pretty normal occurrence for things to fail in a spectacular fashion for me. It’s what’s driven me to become so meticulous about maintenance! Despite my efforts, the spectacles continue to flourish.

Post by **MoVolvos** » 08 Jan 2022, 01:49

- Pete - wrote: ↑08 Jan 2022, 01:22 Well, it wasn’t fully “exploded”. I helped it a little bit.

It was -25ish yesterday morning when death came for this BG. No warnings, no odd noises like you’d expect from an empty transfer case. It all happened in about 4 seconds. The car felt lethargic, kept slowing despite constant go-pedal pressure. Clunk, bang, crack, grossness-Maximus et.al clattering de-bõn-qüee-quēę. Wet t-case & the smell of stinky stiff burning off of the downpipe. When I brought it into the shop this morning, that’s when I head a loud CRACK. I assume that’s when the case busted.

If you can see the video atop the first post, you will see what the case looked like prior to me “helping” it.

It’s a pretty normal occurrence for things to fail in a spectacular fashion for me. It’s what’s driven me to become so meticulous about maintenance! Despite my efforts, the spectacles continue to flourish.

You can see the seepage in some of the areas for sure. Are you sure you put in gear oil and not used the grease gun

? From the looks of it whatever was left and splatted out looks like it been churning and buttering up for sometime. If only JBWeld...

.

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Post by **abscate** » 08 Jan 2022, 01:57

I think just a high mileage , end of life failure of that bearing race as you pointed out.

Kudos to getting her back together so quickly!