The amazing exploding splined disconnect.

[fishsticks]

Yeah, so, I guess I need to fix this.





Thought I just popped a weld and toasted a bearing or two. Nope. Guess when I welded the assembly together I managed to screw up whatever heat treatment was there. Both the collar and the inner gear exploded. The splines on the intermediate shaft are OK.

The housing is OK, so I'm ordering the AWD sleeve and going to try that.

I'm ordering parts to get the Camaro back on the road as well. I may need a driver.

This is the last money I'm spending on the IFS. If I can't make it live with this setup then it's time to start looking for a D44.

[janesy86]

Wow. Hopefully you can get it to work for you once you fix it all up.

...then it's time to start looking for a D44.

But, I do like these words! Man I wish I had the skillz to get a D44 under the front.

[Trail X]

Interesting, both the ring and the inner gear exploded?

If the inner gear exploded, I doubt it had anything to do with the weld you did.

My bet is that the gears were designed to handle the torque of 1/2 of the engine output. By putting the locker in, you allow it to take 100% of the engine output. Torque applied to the splines creates tremendous tensile hoop stresses in the gears, that could be the failure mode.

[fishsticks]

Interesting, both the ring and the inner gear exploded?

If the inner gear exploded, I doubt it had anything to do with the weld you did.

My bet is that the gears were designed to handle the torque of 1/2 of the engine output. By putting the locker in, you allow it to take 100% of the engine output. Torque applied to the splines creates tremendous tensile hoop stresses in the gears, that could be the failure mode.

You're probably right... hoping the AWD sleeve, which I'm assuming is designed for full time use as well as sudden engagement of the front driveline, will hold up.

[bgwolfpack]

You're probably right... hoping the AWD sleeve, which I'm assuming is designed for full time use as well as sudden engagement of the front driveline, will hold up.

What is the difference between the sleeves?

[fishsticks]

You're probably right... hoping the AWD sleeve, which I'm assuming is designed for full time use as well as sudden engagement of the front driveline, will hold up.

What is the difference between the sleeves?

No splines, no collar. Just one piece that joins the intermediate shaft to the axle. The whole assembly gets support from all 3 bearings inside the housing... all the time.

[Trail X]

No splines, no collar. Just one piece that joins the intermediate shaft to the axle. The whole assembly gets support from all 3 bearings inside the housing... all the time.

Probably the biggest benefit!

[bgwolfpack]

No splines, no collar. Just one piece that joins the intermediate shaft to the axle. The whole assembly gets support from all 3 bearings inside the housing... all the time.

Got it.

[KE7WOX]

Interesting, both the ring and the inner gear exploded?

If the inner gear exploded, I doubt it had anything to do with the weld you did.

My bet is that the gears were designed to handle the torque of 1/2 of the engine output. By putting the locker in, you allow it to take 100% of the engine output. Torque applied to the splines creates tremendous tensile hoop stresses in the gears, that could be the failure mode.

Let's send them to someone who is specialized in materials science, this is like porn to them.

[fishsticks]

Interesting, both the ring and the inner gear exploded?

If the inner gear exploded, I doubt it had anything to do with the weld you did.

My bet is that the gears were designed to handle the torque of 1/2 of the engine output. By putting the locker in, you allow it to take 100% of the engine output. Torque applied to the splines creates tremendous tensile hoop stresses in the gears, that could be the failure mode.

Let's send them to someone who is specialized in materials science, this is like porn to them.

Too bad there isn't enough left to send....hehe.

I still stand by my original hypothesis... I had that thing red hot when I was welding on it.

[Jon A]

Yeah, any time you do that you can throw the heat treat out the window. I think you'll have a lot better luck with the sleeve.

In any case, I have to say I'm "happy?" to see you breaking stuff other than the front diff. The other stuff is easy to replace. It's good to see the diff isn't the glass jaw of the system.

[fishsticks]

Yeah, any time you do that you can throw the heat treat out the window. I think you'll have a lot better luck with the sleeve.

In any case, I have to say I'm "happy?" to see you breaking stuff other than the front diff. The other stuff is easy to replace. It's good to see the diff isn't the glass jaw of the system.

Totally agree...the other fixes are cheap in comparison. I can pack a spare CV shaft(or even a disconnect) a lot easier than a spare diff.

[bgwolfpack]

Got any updates on this?

[fishsticks]

Still waiting on parts.... truck is in the driveway on stands...

[fishsticks]

The answer.... (hopefully).

[HARDTRAILZ]

Where was the cheapest to find this?

[fishsticks]

Where was the cheapest to find this?

GMPD ended up being the cheapest after shipping.... but it took them forever to get it to me. They may be a faster ship to you.

[wink]

.... but it took them forever to get it to me.

I received mine pretty quickly.

[Mudwheelin]

I'm sold on this awd sleeve. I have to ask...what's the part number for it? I've googled this thing and can't seem to find the right part.

[DirtyBacon04]

ya gotta look up parts for a buick rainier or Olds Bravada. TB's and Envoys were not avaliable w/ AWD. I'm sure fish could get you the actual p/n though.

I know the whole disco assy p/n is ATP 111002, but if im correct, you're just looking for the internal sleeve.