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07-12-2010, 08:05 PM | #1 |
The Fabricator
Join Date: Dec 2006
Posts: 2,016
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G2 Gas Rear End Broken Gear Teeth/Chattering
I was out driving my cart today when a sudden loud chattering began in the rear end. I took the belt off to spin the secondary by hand. There are rough spots and it makes a loud metal chattering sound. I decided something was seriously wrong and decided to pull the rear end. I drained the oil and it looks grainy. When I split the rear end apart the first thing I noticed were broken teeth on the two main gears. Underneath the spider gear assembly was a pile of broken metal shrapnel. I am not able to tell what the carnage is from exactly. The only recognizable piece looks like a washer. The gears must have churned the debris up and thats how they broke their teeth? I might be lucky and have some parts from a spare g2 diff. Any ideas what happened and what needs to be replaced? I will post some pics.
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07-12-2010, 08:18 PM | #2 |
The Fabricator
Join Date: Dec 2006
Posts: 2,016
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Re: G2 Gas Rear End Broken Gear Teeth/Chattering
Broken Debris
Grainy oil Chipped Gear teeth Are these gears suppose to not touch? Thanks |
07-12-2010, 11:20 PM | #3 |
The Fabricator
Join Date: Dec 2006
Posts: 2,016
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Re: G2 Gas Rear End Broken Gear Teeth/Chattering
Is there a blow up diagram for the g2/g9 rear end? I really need help and cant find much info. Thanks
Edit-was able to find a diagram on another site. Still wondering where that debris came from? |
07-13-2010, 01:53 AM | #4 | |
Not Yet Wild
Join Date: Apr 2010
Location: Bothell Washington About 20 miles north of Seattle
Posts: 68
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Re: G2 Gas Rear End Broken Gear Teeth/Chattering
Quote:
Been there on Toyota pickups. Not sure what caused yours, but I do have a service manual if that would help at all. Just get me your email and I'll send it right over. Best of luck with the rebuild! |
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07-13-2010, 02:06 AM | #5 |
The Fabricator
Join Date: Dec 2006
Posts: 2,016
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Re: G2 Gas Rear End Broken Gear Teeth/Chattering
Ohh did you say toyota pickups? My baby is a 91 4x4 just got a new reman 22re engine, camper top and paint job!
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07-13-2010, 06:42 PM | #6 |
Sometime's............
Join Date: Oct 2007
Location: Tacoma Washington
Posts: 11,875
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Re: G2 Gas Rear End Broken Gear Teeth/Chattering
Is this the rear end your welded the spider gears? That looks like one of the "thrust washers" for input of f/r gear shafts, that doesn't make sence. Did you use a gasket (for case halves) or RTV? Did you bypass the govenor? Did you take out the govenor weights/fork? Good pix's but wish I was there to help. Keep us posted.
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07-13-2010, 07:21 PM | #7 |
The Fabricator
Join Date: Dec 2006
Posts: 2,016
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Re: G2 Gas Rear End Broken Gear Teeth/Chattering
Yes it's the rear end with the welded spiders. I used RTV to seal the case. I did remove the governor weights. Last time I had this diff apart was to take out the high speed gears and reinstall stock gears. The washers tend to fall off the shafts when I split the case apart. All I could think possibly happened was I missed one that fell under a gear?
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