Front diff replacement under warranty?

[isuzurover]

So have any/many D3/4 front diffs been replaced under warranty?

Apparently they are almost identical to a ford ranger front, however have an alloy case instead of the steel case the ranger has.

The alloy cases have apparently been causing a lot of problems (including premature wear) in other makes...

[Learner]

Why should an alloy case "cause" wear?

Thanks,
Peter

[isuzurover]

Why should an alloy case "cause" wear?

Thanks,
Peter

The word from automotive engineering contacts is the alloy cases for many diffs see too much thermal expansion causing the diff to lose bearing preload.

Aluminium has twice the rate of thermal expansion of cast iron or steel.

[TerryO]

So I guess that begs the question, does the Ford Ranger diff with the steel casing fit in the D3 housing and is it compatible?

[isuzurover]

So I guess that begs the question, does the Ford Ranger diff with the steel casing fit in the D3 housing and is it compatible?

Indeed. Of course if none are failing or wearing excessively it is a moot point. However for anyone who plans keeping a D3 long term it may be of interest.

Certainly anyone fitting an ARB locker may be better advised to fit a Ford Ranger diff and then fit an ARB to that to ensure maximum strength.

[TerryO]

There has been several story's on here of diffs failing in D3's, that is why I asked. Would be good to know in advance just in case.

[isuzurover]

I hadn't heard - hence the question.
But a quick google seems to suggest it is a common problem:
DISCO3.CO.UK - View topic - Vibration/grinding rumble from front of disco (http://www.disco3.co.uk/forum/topic86313.html)
http://www.aulro.com/afvb/d3-d4-rrs/127614-front-diff-rebuild-kit.html

Looks like some - or maybe US - ford Rangers also have an alloy case front diff:
https://www.aulro.com/afvb/images/imported/2014/08/1020.jpg
Does this look anything like the D3/4 front diff?

Can't find a pic of the steel case version...

[SBD4]

Looks like they are completely different - note that the ratio is dependent on the engine type:
http://www.aulro.com/afvb/attachment.php?attachmentid=81961&stc=1&d=1407788037

http://www.aulro.com/afvb/attachment.php?attachmentid=81962&stc=1&d=1407788037

[isuzurover]

Looks like they are completely different ...

That was just a random picture I found on the web. The comment came from an arb engineer who said the two diffs were almost identical. I am not sure if that extends to external mounting brackets, hence the question.

from searching though, it sounds like all aluminum case diffs in 4x4s have issues though.