Snapped Differential Bolt

[Chris-S]

Had two diff bolt (the bolt that holds the diff together) failures on Friday night, checked everything, cant see anything wrong. Anyone had anything similar happen or any suggestions what it could be ?

[PaulRotheram]

Good job on snapping them! Not personally heard of that failing, especially twice!
Have you set the diff too tight? Incorrect slipper setting? Might be putting the gearbox under too much strain maybe?

[mikeyscott]

I've snapped two over a season, certainly not two in one night.

Indeed I'd look at too tight slipper as I've killed two diffs at the weekend from an incorrect slipper setting.

Diff rebuilds this week and then start again

[Dazzler]

I experienced this same problem when I first had my Cat. At first to get back out on track I just replaced the bolt, then the second one snapped and the third would not tighten the diff. The Circlip inside had worked out of its grove and can only assume that whilst doing this it was applying an uneven load under the head of the bolt and caused it to fatigue during opperation. So, take the diff appart and check the circlip is not just seated in the groove, but also tight in there (As has been advised in other posts on here).

[Big G]

sounds like too much is being asked of the bolts. my slipper tends only to make it's noise on carpet with mega traction. outdoors it rarely slips. I haven't broken any bolts in my cat touch wood

[bigred5765]

seen a few snapped,but its usually builder error, ether using 2 drivers to tighten up the bolt and grub screw againts each other, or over tigthening it in build process,

[madmax]

ive had one snap on me in the past and mine was down to the compresion washers loosing their tension. i replaced them and not had a problem since.

[Big G]

can't we just fit a spring to it like a AE diff?

[Trish]

I think I can help you.

The problem you are experiencing is a simple fix, The Spring washers you use as a four can flatten and should be replaced when you notice the diff starts to undo itself. When they are flattened and the diff is put under load the springs would normaly compress if you have gone past its threshold but as they are flat and you keep tightening it up the bolt receives the grunt and snaps.

I had the Same problem and when i changed the springs which is the cheapest part of the diff I had no problems afterwards.

[Chris-S]

Thanks for all the help.

Trish, did notice the diff started chirruping, got a new set of beveled washers. I'll rebuild that tonight, got a spare diff as well. When I ran TC last year, i'd back off the diff between meetings, not easy to do it in the cougar without pulling the diff out.

[Chris-S]

Quick update, rebuilt the diff with new washers, feels like new again. See how it goes tonight at Taplow