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Cracked cast iron rear differential cover

Tiny
SHARLENE HELLBERG
  • MEMBER
  • 2002 CHEVROLET TAHOE
  • 16,000 MILES
Our 2002 chev tahoe experienced a crack in the rear differential cast iron case. It has been replaced twice, and is ready for a third time. Looking for solution to repeated cast iron case cracking. It occurs in the same place each time, about 1:00 just about the cover. We are ready for the 4th differential and would like to make this repair the last-suggestions?
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Friday, January 13th, 2012 AT 9:38 PM

6 Replies

Tiny
HMAC300
  • MECHANIC
  • 48,601 POSTS
Can you pin it down to when it cracks?Like in icy conditions? I would have to think that something is out of line causeing this.
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Saturday, January 14th, 2012 AT 12:45 AM
Tiny
SHARLENE HELLBERG
  • MEMBER
  • 2 POSTS
We live in the desert and very rarely have icy conditions. We do travel on dirt roads. The history is first the cover cracks, and is replaced, and a while later the cast iron case cracks. Last replacement was 4/2011 with a salvage part. Being out of line seems logical, although I do not know what is out of alignment or how to correct. A heavy duty cover has been suggested to give a little more stability to the pumpkin. Dirt roads are washboarded. Should tire pressure be adjusted to give a little more give? It has happened summer, spring, & winter so no help with weather.
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Saturday, January 14th, 2012 AT 2:07 AM
Tiny
HMAC300
  • MECHANIC
  • 48,601 POSTS
It may be the washboarded road then and replacing with a heavy duty cover is agreat idea. You might try the tire thing, but be aware it will wear the tires sooner by doing that. How fast are you driving over the washboarded conditions? Maybe slowing down a little would help as well. Also check your trailing arm bushings, they may be wornout causing this problem.
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Saturday, January 14th, 2012 AT 3:14 PM
Tiny
SHARLENE HELLBERG
  • MEMBER
  • 2 POSTS
Traveling 25 miles out dirt roads that are graded about every other month at a speed 45 to 50 mph is just fast enough to smooth things out a little and slowing rattles and is too rough of a ride. I am sure that the trailing arms are some of the parts that we removed to change the rear end, but could you give me some help in identifying. That bushing idea sounds logical and would have had to be going on for some time to create the same break. It would sure be nice to change it again for the last time.
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Sunday, January 15th, 2012 AT 1:35 AM
Tiny
HMAC300
  • MECHANIC
  • 48,601 POSTS
The trailing arms are what hold the reare end in place. They have bushing in both ends so both ends would need to be inspected. You could possibly go to urethane bushing bu t that would stiffen the ride up and maybe break teh rear end even faster. You would have two on top and two on bottom of the axle. Connecting to the body. Also check where they are welded to the mounts are welded tothe body, then could be cracked as well.
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Sunday, January 15th, 2012 AT 2:50 PM
Tiny
GASCAP
  • MEMBER
  • 9 POSTS
So you have replaced four rear ends correct?That's a whole lot a time and money, so i'm not sure what to suggest accept a H1
Humvee just kidding. Is your Tahoe 4wd or 2wd if its a 4x4 I would strongly suggest that you upgrade to an after market unit made for off road duty. Expensive but lots less money than 4 GM rear ends + labor that are apparently not up to the task. As far as an HD cover I do not see how this would do anything but waste more money, seriously if its cracking almost an inch thick of cast iron wtf is some polished aluminum going to do to help?If its a 2wd well I would guess that's the problem simply put 2wd suspensions generally are not suited for daily off road use not to say factory 4x4's are either but with added ride height, better goodies underneath they stand a better chance. Since you live in the dessert many local specialty truck n SUV will fix you up with precisely what you need. Might even throw in that fancy polished HD diff cover for free. After seeing how pretty y'all are. Sorry couldn't help my self can take the gentleman outta the country, but never the country outta the gentleman. Thank you folks. Gascap
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Saturday, January 12th, 2013 AT 12:14 PM

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