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Originally Posted by f5fstop
What happen is if you meet a maximum restriction such as a boulder, tree under water, etc., and you apply a lot of engine torque to go over the obstacle, the front diff tends to flex (it's aluminum), thus allowing the pinion gear to ride up over the ring, and start chipping teeth. Once this starts, it is not long before they start breaking.
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This is the exact info I've been looking for to give to my service guys. They are completely in the dark about this issue.
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Originally Posted by f5fstop
Newer vehicles, and service parts diffs and ring/pinion gear sets have been hardened to help reduce front diff failure, but I personally don't think it is the true cure for those who really off-road on extreme trails.
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So both Bebe and I should be getting the newer gears this time around. Time will tell if its a real fix or not.