Front Differential Problems

I've had 3 front diff put in under the extended service warranty.....still having issues, front end locks up in 4WD and will not disengage "easily"..... the last time it disengaged I had a loud and powerful BANG come from under my feet and felt like the truck came off the ground......dealership said "there were metal particles in the gearbox oil when they opened it up"......NO FOOLING?!?!?

I stopped the truck, got out and looked underneath to see if I still had any of the front power train attached to the vehicle!

Sending it back again soon, still not right and now I'm seeing oil spots in my driveway where there were none before, the regular Italian broom won't clear them, have to resort to the Italian Power Broom

 

Sorry man. That sucks!

 

OP, any resolution? I am test-driving a 2010 now that has less severe, yet similar, front shuddering at around 20 mph. It's a long shot, but am wondering what solved your issue?

 

What the OP describes is disengaging the 4wd when it's under torque. Usually it's caused by being on pavement or some other hard very grippy surface and turning. I got my '07 tundra cheap because the previous owner stretched the chain inside the transfer case because they were driving the truck like it was AWD, not 4wd.

sdd4n, what I think you are describing (I don't have it so I can confirm) is a bearing in the front diff that's worn out. I think the replacement is a bushing vs a bearing.
https://eastcoastgearsupply.com/files/PDF Files/tsb-0121-08-t9r-front-diff-growl.pdf

 

Is it a vibration that happens around 15mph to around 30 mph. If so it might be what Dr_Al said . I just recently replaced my needle bearing with the bushing that East coast gear supply offers . It had the same sort of noise you are describing around 15 to 30mph .

 

I use 4wd almost daily and noticed mine was making loud nose going in and out of 4wd. Now I only put it in and out of 4wd while it's in neutral. Seems to go in and out seamlessly now. Just wanted to share my experience

 

I do the exact same when I switch into 4wd. I always completely stop and shift into netural and then switch to 4wd.

 

Common sense again people... engage 4x4 below 20mph and disengage while coasting. That's not in the book but it should be.

 

Ugh, I'm 2wd though (the one I'm looking to buy).

 

Front diff thread - asking for a 2wd lol

 

A question to add to this I have a 13 crewmax rock warrior I've leveled the front with bilstien 5150 shocks on the highest setting starting hearing the famous needler bearing roar so got ahead of it I thought and switched it with the ECGS sleeve replacement changed diff fluid while I was in there. Now I'm still getting a slight roaring noise form it at slow down speeds and it's driving me crazy any one have a solution

 

Currently I am having that issue with the roaring sound and then changing back and forth with 4hi. Noise goes away when it's in 4hi, noise comes back when back on 2wd. Read a lot about ecgs and hear this is a common issue with people owning Toyotas with needle bearing replacements. For a couple of months I thought it was just the tire or tires. I've done the alignment and rebalance all 4 wheels but still there. I went ahead and bought all what I need from ecgs. I am currently on a time crunch too since I have to move in February.
So my question is, for anyone who has dealt with this issue, how common is it to have the differential needing replacement if the bearing is bad? If that's the case I'm F'd cause I'm definitely required to move in Feb with my family if you catch my drift. I have been driving it around (work is like 5 min away from where I live) so not far at all. And we're trying to sell the other car (09 Honda Civic). I wouldn't mind taking it to someone to fix it just cause I'm on a time crunch, course I'm at the mercy of their schedule and dealing with any incompetent mechanics.
Anywho apologize for the novel, lots going on my end. Just trying everything done in a timely manner.