Front differential problem when turning. Loud clunk.

Hi all,

When turning left or right I have a horrible clunk in the front end. The whole front end jumps up and down. Seems to drive ok in 2wd. The truck is a 2016 dclb trd Or. It is still under warranty. I had a local mechanic look at it. He seemed to think it was an issue in the front diff. Said the axle was very loose where it goes into the diff. He had me tow it to the closest dealer. They said the issue was "because of the 2" lift a bolt has pulled through the frame and is causing the transfer case to hit the differential" . I am waiting to see if the warranty is covering the repair. Has anyone ever heard of this? I spoke with my mechanic again and he said it sounds a little bit weird because the issue is inside the differential.

 

the transfer case is nowhere near the front differential. Either the person relaying the info to you has no idea what they're talking about or they're making some shit up. Either one is likely from a dealership unless you talk to the technician directly. The axle play into the diff sounds like a bad needle bearing which is pretty common especially after a lift. But for the whole front end to be jumping up/down, that sounds like something else. You're not using 4wd and making turns on dry pavement are you?

 

Sounds like you have a front lunch box locker

Seriously though, it does sound like it may be or have been stuck in 4wd and that's what's causing the issue. It may not be coming out of 4wd. Is there any lights on warnign signs on your dash at all?

 

I only use 4wd on snow or ice here in vt. Happens on snow covered roads. My warranty company seems to think they said the transfer case was hitting the transmission. Haven't been able to talk with the service tech directly. It shifts back to 2wd as it should. No warning lights. I guess the warranty company (allstate) sent an adjuster out to take pics etc. Odd to me. Happenned all of a sudden one day pulling into a parking spot on ice. Started with a thump. Reason points to an axle or differential.

 

Should rename the thread “How To: DIY front locker.” Seriously though OP, like others have mentioned play where the CV goes into the front diff on the driver side sounds like a shot needle bearing. Common after lift. Easy fix.

 

Now the transmission is hitting the transfer case? They are attached.

What kind of warrantee are you referring to? Is this a factory extended?

 

He said before that it was Allstate. I predict that his extended “warranty” will tell him to pound sand

 

I bought a bumper to bumper warranty for 7 years 120k with the truck. The repair is under review because the dealer says that the damage was caused by the 2" lift. Has a diff drop installed. Even though both allstate and the dealer said the lift wouldn't void the warranty. Haha. It was installed at about 500 miles. I know the transfer case is attacyhed to the transmission. No idea what is going on at the toyota service dept. The only things I could find searching forums were pinion or cv issues at the diff.

 

Update from the dealer was that a bolt on the differential has pulled through the frame and the frame has cracks on it. Seems odd to me. The truck hasn't been offroad since last summer and that is light enough. Seems like some heavy offroading could cause that? Anyone else experience this?

 

I have not heard of such a thing. Post pics.

 

Please tell us you responded to the dealer " I'll be there in 20 mins to take a look" " I would like the tech to show me exactly what they are speaking about" Do this before ANY work commences. They may say they can't due to insurance, but in fact they can when they escort you to your truck. Take some photos.
Honestly its smells a bit shitty. Never heard of such a thing. Good luck.

 

The words here are all wrong......

1) either you're not understanding
2) you have something highly unusual happening
3) someone is blowing smoke up your skirt

You bought an aftermarket warranty a flim flam finance guy hustled you based on fear. Those don't always work out well most times.

Hoping the best for you. In for a real explanation, pictures, final resolution.

 

∆ This ∆

 

I've seen the diff mounts rip out and destroy the frame when using a diff drop.

 

Seems most likely a mount is broken, loose, or improperly installed somewhere.

 

pics?

 

I second this
(Something along the lines of this Broken Front Diff Mount | Tacoma World )

 

Update. So no warranty coverage of course...just had the truck on the lift at my local mechanics place. The rear bolt where the differential mounts to the frame had pushed upward and cracked the mount. My mechanic said it looked like the bolt was loose. Probably from when the truck was built. over time with the vibration it pushed the mount upward. The noise i heard was the driveshaft rubbing on the bellhousing. The fix is going to require some cutting and welding.
The image is of the bottom of the mount. They are going to remove a piece in order to insert a plate above and weld the piece back on. Everyone may want to check that bolt to make sure its tight.

 

Get rid of the diff drop

 

Ya it's not totally clear based on the OP's description, but it sure sounds like the diff drop was defective or installed wrong. if so, there's no reason that should be covered by a warranty from Toyota or an extended warranty purchased before the lift. Even a warranty purchased after the lift was installed probably does not cover the lift or the installation of the lift unless it came from the installer and/or lift manufacturer.

One note, OP, your entire warranty is not voided, in case that's not obvious. It just doesn't cover aftermarket parts, their installations, nor (I think) installations of OEM parts by non Toyota certified shops. But you need to read warranty to know exactly what it covers. They are not all the same. You get the promise you paid for and no more.