The rear gears in the Zuk axle suffered a catastrophic ring and pinion failure. Due to some significant chipping on the edge of the pinion and a warped ring gear or carrier. My guess is a chip came off the pinion, which chewed up the ring and pinion and the rest is history.
Luckily I have parts, so I stripped out the aluminum 3rd member out of the front of a spare axle. Swapped out the 22 spline front side gears for 26 spline rear side rears. Welded up the spider gears to 'Fozi Lock' the rear - there no way I'm running open differentials ;)
I decided to 'Fozi Lock' it (weld 2 spider gear teeth, miss 2 teeth, and so on) as apposed to 'Lincoln Lock' (fully weld the gears). Pros and cons of both methods here;
http://www.offroaders.com/tech/Lincoln-Lockers-Fozzy-Locker.htm
I started to button up the 3rd and torqued down the cap bolts...and boom! I threaded a cap bolt in the aluminum housing. I was using service manual torque specs, so it should have been fine. The housing is ruined, so everything got swapped into the Samurai steel housing after all! It'll be stronger like that ;-)
I got it all installed back into the axle housing, RTV sealant and all. I was
cleaning up the workbench....the cross pin cap was lying there, taunting me. So it all had to come out again in order to install that.
3rd is in now for the final time. I also took the opportunity to install 3 new Maruti Gypsy (Indian Suzuki SJ410 LWB) transfer case mounts to replace the hockey pucks.
Test drive is good so far, and it's much much quieter with no warped ring gear and proper transfer case mounts :-)
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