Exploded IFS! pics

[blindellh2]

It all started by helping someone that was stuck in a mud hole. I had the confidence in pulling him out.
After a couple of attempts in 4lo rear locked, in a slippery snowy surface... Someone noticed a puddle of oil.
Was still powering the rear wheels UNTIL i pulled back onto pavement and decided to pull it out of 4HI locked to 4HI. Then all of a sudden it would not power any wheels! Tried 4LO locked and reverse. Nothing at all. Had to be towed home.
Bought a front diff from an 04 2500HD and is totally different than my front case!
Im still in need of a good used front diff case...
heres some pics:

[Hellz]

all i can say is ouch!

[blindellh2]

Does this occur much in H2's?

[citiboy]

I've broken right front half-shaft twice on the trails....i need to replace the left front half-shaft because it's making noise while turning....i never break the front diff. yet (knock on wood).

[HummerJim]

I've never seen a front diff break like that on an H2. Did it come down on a rock or hard object?

[guruerror]

Originally Posted by blindellh2

Does this occur much in H2's?

I wouldn't say it happens a lot...this is the first I've heard of it (and I cruise several different forums); but I'm sure it has happened before. Just as I'm sure it's happened on other brands of trucks...
...they might look like tanks; but they're not. LOL...they're just a truck.

Wow...that sucker can get expensive:
http://parts.nalleygmc.com/showAssem...d ifferential

Originally Posted by HummerJim

I've never seen a front diff break like that on an H2. Did it come down on a rock or hard object?

I'm betting he was at a high RPM in that snow and then it caught something to bite on...and BOOM!

[Hellz]

the good news is.. it just looks like he needs a new housing. most likely can reuse alot of parts off his old one to help cut down on the costs.


whoknows, it might have been a defect in the housing.. i.e a hairline crack somewhere that just gave out when the right amount of force when he was pulling the other vehicle out.

those are pretty clean break lines on the housing...im assuming the vehicle is out of warrantry, but who knows... have it checked out. might get lucky.

[guruerror]

Originally Posted by Hellz

the good news is.. it just looks like he needs a new housing. most likely can reuse alot of parts off his old one to help cut down on the costs.


whoknows, it might have been a defect in the housing.. i.e a hairline crack somewhere that just gave out when the right amount of force when he was pulling the other vehicle out.

those are pretty clean break lines on the housing...im assuming the vehicle is out of warrantry, but who knows... have it checked out. might get lucky.

Yeah...but that housing is listed at $800+

[blindellh2]

Originally Posted by HummerJim

I've never seen a front diff break like that on an H2. Did it come down on a rock or hard object?

It was on a flat surface trying to pull someone out of the mud...

Originally Posted by guruerror

I wouldn't say it happens a lot...this is the first I've heard of it (and I cruise several different forums); but I'm sure it has happened before. Just as I'm sure it's happened on other brands of trucks...
...they might look like tanks; but they're not. LOL...they're just a truck.

Wow...that sucker can get expensive:
http://parts.nalleygmc.com/showAssem...d ifferential

I'm betting he was at a high RPM in that snow and then it caught something to bite on...and BOOM!

traction 2 kept me down below 3500...
That sucker is very expensive.
I pulled a noob move and went to the salvage yard looking for a silverado 2500HD 9.25" diff. THEY DO NOT INTERCHANGE.
So i bought a whole new bare housing today and going to do 4.88's front and rear with possibly and E-Locker front...

[guruerror]

Post back your results, especially if you go with a locker. I've been 'thinking' about it too.

[H2ummer]

That sucks. I know first hand. Climbing a hill in 4WD low lock. Steady and not agreesive when I heard a pop and smelled the fluid. Dropped the front skid and... well the pics speak for themselves.

[citiboy]

Originally Posted by blindellh2

2500HD 9.25" diff. THEY DO NOT INTERCHANGE.
So i bought a whole new bare housing today and going to do 4.88's front and rear with possibly and E-Locker front...

That's the same route i'm goin' to do....yukon 4.88 with eaton e-locker....good luck with the build and post your results.

[citiboy]

Oh man, another one....this really sucks...i feel bad for you guys. I don't understand, why the half-shaft never give first before the diff....i've blown 2 half-shaft and my diff. still in good shape.

[pdxrealtor]

Those pictures make me cringe...... good karma on you for helping a guy out, but damn .................

[ROUSHDEMON]

Holy cow that sucks........ Hope you can get it all fixed up soon, those pics is like watching skaters braking bones.....

[pdxrealtor]

Speaking of skaters did you all see Lindsay Vaughn's accident???

Oh..... that hurt!

[working Hummer]

mine exploded exactly like that...I wheel hopped going up a dirt hill and that's all she wrote...

[blindellh2]

I hear this is sort of common on 03-04 diff cases.
I just received my new diff case last night. I am only waiting on gears and master overhaul kit now.
I will keep updating with pics and all on the progress.

Originally Posted by H2ummer

That sucks. I know first hand. Climbing a hill in 4WD low lock. Steady and not agreesive when I heard a pop and smelled the fluid. Dropped the front skid and... well the pics speak for themselves.

Did you buy a totally new front diff when this happened or did you rebuild with a new case and salvage most of what you had already?

[Easy Ed]

I was thinking there were some post back in the early years on here about the problem but could not find them May have been on the old board and did not make it to this one.

I also thought that the new cases had different reinforcement ribs to them, does your new case look different than the old one (besides being broke in two ) by having extra ribs in the casting ?

Thanks and good luck, Ed

Found a link that DRTYFN made a post to 1/20/2004 http://www.elcovaforums.com/forums/s...ad.php?t=12515

Originally Posted by blindellh2

I hear this is sort of common on 03-04 diff cases.

[SummitUp]

Originally Posted by Easy Ed

I was thinking there were some post back in the early years on here about the problem but could not find them May have been on the old board and did not make it to this one.

<This Thread> might be the one you're referring to.

Originally Posted by Easy Ed

I also thought that the new cases had different reinforcement ribs to them, does your new case look different than the old one (besides being broke in two ) by having extra ribs in the casting?

Consensus is that there was definitely a design change beginning in '05 which included adding the extra ribs in the casing. I've only seen this problem occur in the '03 and '04 years.