Front diff bracket broken

[Vegas Runner]

It turns out my oil pan was damaged also. It has a crack in it from being struck by the differential. So it is being replaced also. All of this resulting from a bracket I did not know was broken. I would reccomend everyone look at their differential support brackets. I am not the first person to break one of these brackets then drive on it for some time not knowing it was broken resulting in additional damage.

[bulldog]

That blows, what skids are you running? It probably had issues before BBB and John Bull probably just pushed it over the edge.

Maybe it is just something in the water in Vegas??

On a serious note, it is a very good point beign raised about vehicle inspection from time to time. After and before trips and during an oil change would be good times.

[Vegas Runner]

My skids pretty much protect the bracket. It is possible the damage was done before I had the skids. Or it is possible the bracket breaks from hard duty in general and is not a result of a direct impact.

[expat]

Looks like another product for the aftermarket! I would think the design could be improved too, as well as the material.

[bulldog]

Originally Posted by expat

Looks like another product for the aftermarket! I would think the design could be improved too, as well as the material.

Good point!! Something of better material would do a much better job. Not sure why we have seen 2 failures now.

[expat]

I've got my own ideas but what would people suggest is the best way to inspect. I know that those who have broken these darn things were totally unaware of any damage prior and as Ed mentioned his even had some rust.

I wonder if my suspension woes are due to this...eeeekkk...I better get up early in am and check it out!

[Mikestang]

After reading about Robert's breaking I check mine out with a good light at each oil change, looking for hair line cracks or fatigue. I also "tap" things on the with a rubber mallet and listen for rattles, stuff like that.

[my034runner]

Originally Posted by expat

Looks like another product for the aftermarket! I would think the design could be improved too, as well as the material.

Originally Posted by bulldog

Good point!! Something of better material would do a much better job. Not sure why we have seen 2 failures now.

It definitely needs to better designed, some sort of heavier dom maybe, would be good.
The design of the front diff support bracket #1 is much stronger, even though it's the same material.

Can we move the discussion of this bracket to a new thread? We definitely need to visit this topic, separately from this topic.

[my034runner]

Thanks for moving it Andries.....

[Vegas Runner]

Originally Posted by expat

I've got my own ideas but what would people suggest is the best way to inspect. I know that those who have broken these darn things were totally unaware of any damage prior and as Ed mentioned his even had some rust.

I wonder if my suspension woes are due to this...eeeekkk...I better get up early in am and check it out!

Mine was clearly broken in two pieces. A visual inspection would have done it.

[06SSTaco]

Originally Posted by Vegas Runner

Mine was clearly broken in two pieces. A visual inspection would have done it.

Ed, I also noticed as you did, when looking at the support it just looks weak & chincy. I would of thought that such a critical component would have beeen better built.

I'm going to inspect mine this weekend and regularly thereafter and especially after any kind of hard impact to the front suspension that results in suspention bottoming hard to the bumpstops it seeems to me that would be the most likely cause of breaking the support. What do you think?

[Vegas Runner]

Originally Posted by 06SSTaco

I'm going to inspect mine this weekend and regularly thereafter and especially after any kind of hard impact to the front suspension that results in suspention bottoming hard to the bumpstops it seeems to me that would be the most likely cause of breaking the support. What do you think?

Hard to say exactly what caused it. It does seem to be in an unlikely position for a direct impact to the bracket (e.g. rock) to cause the break. As you say it could be just a hard jolt to the suspension. Someone with more insight than me would have to study it.

[bulldog]

Maybe it might be worthwhile to look into having something made aftermarket to replace the stock support. SHouldn't be super expensive to have a trussed support made form steel. The current support is a cast metal, which seem to be very suseptable to hairline fracturesa dn eventually failing completely.

[97kurt]

Originally Posted by bulldog

Maybe it might be worthwhile to look into having something made aftermarket to replace the stock support. SHouldn't be super expensive to have a trussed support made form steel. The current support is a cast metal, which seem to be very suseptable to hairline fracturesa dn eventually failing completely.

Can anyone post of pic of the bracket or the broken bracket? Also in Roberts and Ed's cases, was it the passenger side bracket?

[Mikestang]

One of these days I'll get motivated enough to have my rear control arm brackets welded on. I had planned on having Demello do it. I'll mention this to him at that time and see if they can fab something up.

[Vegas Runner]

Originally Posted by vegaskurt

Can anyone post of pic of the bracket or the broken bracket? Also in Roberts and Ed's cases, was it the passenger side bracket?

It was the passenger side bracket. I will try to post up the page in the repair manual showing the bracket on Monday. Its on page 29-6 of the 2003 manual if anybody gets a chance to post it before then.

[my034runner]

Front Differential support bracket #2 (passenger side).

I posted pics when I broke mine, I'll check and see if I still have them on my WebShots page.

[my034runner]

Here's a couple after they were off.

[IMG][/IMG]

http://rides.webshots.com/album/556580709zgzvtT

[Cruiserhead]

it basically looks like a long, unsupported lever arm. the leverage snapping off at the mounting point. am i looking at that correctly?

is there clearance to make the arm thicker or add a support brace/bolt/additional mounting point in the middle of the arm?

[bulldog]

Originally Posted by Cruiserhead

it basically looks like a long, unsupported lever arm. the leverage snapping off at the mounting point. am i looking at that correctly?

is there clearance to make the arm thicker or add a support brace/bolt/additional mounting point in the middle of the arm?

If the bushing on the diff side can be pressed out, it might be possible to just have a pice of steel machined to repalce the existing arm. The same thickness solid steel will be much stronger.

Great oppertunity for an aftermarket part. I suspect it is only a matter fo time before the FJC crowd will start breaking these (given that the 2 that has broken are form a 03 and 04 that sees regular action).