Differential Housing Failure - Picture Included

[thegeneral101]

On Saturday I was driving my car, and during a fast 1-2 shift (around 5,500 rpm) I heard a huge CLUNK followed by rattling. The car wouldn't move, but would go into neutral. No fluids leaked, but when I looked under the car, it appears as my differential just plain snapped in half....almost hard to believe!

Is this a symptom of the bolt weakness?

In the photo, you'll be able to see where it snapped off toward the top right of the photo. And it looks like some bolt snapped in the lower left.

Really bummed, supposed to take it on a trip this coming weekend

[W///]

Originally Posted by thegeneral101

On Saturday I was driving my car, and during a fast 1-2 shift (around 5,500 rpm) I heard a huge CLUNK followed by rattling. The car wouldn't move, but would go into neutral. No fluids leaked, but when I looked under the car, it appears as my differential just plain snapped in half....almost hard to believe!

Is this a symptom of the bolt weakness?

In the photo, you'll be able to see where it snapped off toward the top right of the photo. And it looks like some bolt snapped in the lower left.

Really bummed, supposed to take it on a trip this coming weekend

It's a 2013 as well? Ouch. How many miles on the car?

[thegeneral101]

Originally Posted by W///

It's a 2013 as well? Ouch. How many miles on the car?

Correct, 2013....about 11,000 miles. Dealership has it as I type this, supposed to get back to me this afternoon.

[W///]

Originally Posted by thegeneral101

Correct, 2013....about 11,000 miles. Dealership has it as I type this, supposed to get back to me this afternoon.

Well at least it was a quick fix!

[thegeneral101]

Originally Posted by W///

Well at least it was a quick fix!

They are going to diagnose it today...pretty sure its not a quick fix haha. I'm curious to see if they stock the parts (which I doubt they do).

[W///]

Originally Posted by thegeneral101

They are going to diagnose it today...pretty sure its not a quick fix haha. I'm curious to see if they stock the parts (which I doubt they do).

Oh I thought you were getting the car back today, sorry read wrong.

[rantarM3]

Maybe you just have a factory M monster motor in that M3. Hope they fix it soon and don't try to give you any grief over it.

[kitw]

I'd guess that a bolt either backed out or was loose and failed and the additional movement broke the mount. Sucks.

[dparm]

Things just break. Nothing is 100% reliable. Hard to say what happened from those photos. Keep us posted, OP.

[Malek@MRF]

More than likely the sub-frame itself is damaged and needs to be replaced as well as the forward mounts are lightly bent or overly stressed. This is a pretty large problem with these cars and something I have been personally preaching for a long time that it needs to be addressed. There is a solution for this, check the threads below.

Check this thread

Check this thread as well...

Also this one.....

And lastly, this thread.

[thegeneral101]

Appreciate all of the input! I'll definitely report back once I hear from service.

[BPMSport]

Wow.. Scary picture. I've always been worried about this happening to me. I never really launch my car but it seems this is happening to non-abused cars...

Good luck with the fix! I'm curious if it had anything to do with bolts not being tightened to factory specs.

[thegeneral101]

Originally Posted by Mike Benvo

Wow.. Scary picture. I've always been worried about this happening to me. I never really launch my car but it seems this is happening to non-abused cars...

Good luck with the fix! I'm curious if it had anything to do with bolts not being tightened to factory specs.

As far as I know, the bolts were never checked (after the vehicle left the factory that is). The only time it has been to the dealer since I purchased it new was for the initial oil change.

As others have suggested, perhaps a bolt walked its way out.

Car is completely stock, excepting an x-pipe.

[Someone?]

I wish i lived Anywhere near Melek, i would drive over and get Solids put in, But im over 2000 miles away.

[Verify]

Buy the Defiv kit and be done with it

[kerrit]

I've had some nasty wheel hop on hard launches and worried about my rear diff bolts breaking at times. plenty of fast 1-2 shifts as well.

I had it up on a lift last week and all looks fine luckily... VERY expensive repair if you have to pay out of pocket for a rear subframe.

[Vic311]

Any history of launching there? Would help to hear how agressive or mild you were with the car.

[BPMSport]

Originally Posted by thegeneral101

As far as I know, the bolts were never checked (after the vehicle left the factory that is). The only time it has been to the dealer since I purchased it new was for the initial oil change.

As others have suggested, perhaps a bolt walked its way out.

Car is completely stock, excepting an x-pipe.

I heard from a couple members that the untouched stock bolts on their car were not torqued to factory tightness specifications.. So yes, it might be a bolt working it's way out, or not being torqued properly to begin with. I'm going to check mine in the next few weeks and will report back. My car is at the dealer right now for a "ting" noise the diff makes on loading and unloading. They said there is a service measure for it that involves a repair kit for the input flange. Hopefully that solves the issue! I'm also very interested in getting the subframe bushings done, but not looking to change the diff bushings as I think the majority of cabin whine comes from those.

[dparm]

Where is the specific bolt(s) that are known to be problematic? A photo would be helpful.

[BPMSport]

Originally Posted by dparm

Where is the specific bolt(s) that are known to be problematic? A photo would be helpful.

It's the two bolts at the top that bolt the diff in. If I recall correctly you can see the one on the drivers side pretty easily. I won't have my car up on a lift until next week but I'm sure someone will have a pic. If not I'll post then. I also contacted a vendor about getting the subframe bushings and I'm hoping he can check the torque on those for me.

[thegeneral101]

Originally Posted by Vic311

Any history of launching there? Would help to hear how agressive or mild you were with the car.

The car, in my opinion, hasn't been driven hard in its lifetime. Always allow warm up, etc...plus its a Lime Rock, so I've tried to take care of it (just in case it holds its value more...I know theres endless debate there). Two launches from 3-4k, and just a bunch of regular aggressive 1-2-3 shifts during acceleration. It's never been tracked either.

[bigjae1976]

6SP or DCT?

I would imagine that a launch would put a lot more stress in this area than track use.