2006 Commando New Style Diffs

[Paiute3]

I just found this on another messageboard. I wonder if the Commando is having the same problems as the Trooper.

Cinda

Post subject: New style diffs to replace in 2006 CommandoPosted:

Posts: 1 Just rec'd 2 new style rear diffs from joyner to replace in the 2006 650 Commando. Need to know how to take the cv cups off old style rear diff that need to be installed in new diffs. Is there any special tools needed or do you have to hold your mouth just right??!!! Any help will be much appreciated. Thanks much

[brostar]

I think your find that the Commando gears in the front and rear diffs where not meshing correctly. In other words one gear would ride on the top of the teeth instead off fitting the gap fully. The result was the tips of the teeth snapped off. Not too dissimilar, different problems with same result. All new Commando from the middle of last year have correctly shimmed diffs.

Cheers Mike.

[Guest Lenny]

Just put a new diff in mine. when I opened up my diff to check for sheared bolts like Kinarfi had, I found a completely mis-shimmed differential and I could see that the pinion gear wasn't correct, In my case the pinion gear was not only too far away from the ring gear but was also pushed in too far torwards the center of the ring gear. This looks to me like it's causing the tips of the pinion to take more then it's fair share of the stress and thus ending up fracturing chips off. I think proper alignment of the pinion gear axeually in relation to the ring gear is even more damaging then improper gear tooth clearance. My teeth were chipped, thus the new differential. Fortunately, I purchased the 3yr extended warranty just as it came available and they covered it. Joyner got a diff out and I received it in 1 day.

Lenny

[Paiute3]

Just put a new diff in mine. when I opened up my diff to check for sheared bolts like Kinarfi had, I found a completely mis-shimmed differential and I could see that the pinion gear wasn't correct, In my case the pinion gear was not only too far away from the ring gear but was also pushed in too far torwards the center of the ring gear. This looks to me like it's causing the tips of the pinion to take more then it's fair share of the stress and thus ending up fracturing chips off. I think proper alignment of the pinion gear axeually in relation to the ring gear is even more damaging then improper gear tooth clearance. My teeth were chipped, thus the new differential. Fortunately, I purchased the 3yr extended warranty just as it came available and they covered it. Joyner got a diff out and I received it in 1 day.

Lenny

Lenny,

Did you open up the new diff?

Cinda

[Guest Lenny]

Lenny,

Did you open up the new diff?

Cinda

Definitely did. Found the same problems. I installed my diff kit in it giving it much stronger bolts and better security from bolts comming loose. I also re-shimmed it for clearance and proper pinion to ring gear alignment. Real happy with how it came out. See my post under Diff blowup.

[brostar]

Lenny, it was my understanding that the Commando diff problems were just the mis-shimmed teeth on the gears. I just wonder that in your case that caused the gears to walk away from their settings slightly making them to far away from the ring rear if that is possiable. I don't think that happened with the Commandos, maybe they snapped because the strength was less than the Troopers. Anylizer might have the inside word with that issue.

Cheers Mike.

[Paiute3]

I would really like to see Joyner step up and take care of the Diff problems. By using bolts of poor quality and the diffs not being made correctly aren't they responsible? Ours is parked until we get Lennys fix it kit. I think that this is a major problem and the second one (the drive-line was the first) in the last year that is either poor workmanship or lack of quality in parts and design. All I can say is thanks to Lenny for all his hard work in keeping all of us on the road.

[Ethan]

Anyone on here have any extra cases for the rear diff on a 06 commando