Front diff overheating and melting steering arms

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cfleming

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Hi I was just wondering if anyone could let me know how a front diff would overheat causing melting damage to the front axle? No towing was involved, was driving and heard a loud bang with a heap of smoke and oil all over the front axle.. Cheers
 
The front diff is always running even in 2wd so i would guess it siezed up and went bang. Not unusual. Double check the ratios when installing replacement as there are several.
 
The front diff in a D40 is always turning over, but as long as the transfer case isn't engaged it shouldn't be a problem.

Therein lies the most common cause. Engaging 4WD and driving on firm surfaces can cause problems, particularly for the front diff which isn't exactly the strongest diff around.
 

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