2003 Outback -- Left Front Axle Came Out of Differential?

[skipatroller]

Hey Folks,

Has any one ever run into this issue or know why it might happen?

The driver's side front axle has popped part way out of the differential. This happened when turning a corner.

The car belongs to my son's fiancee. It is a '03 Outback with 2.5 and 4 speed automatic. She bought it about a year and a half ago. the car now has ~133,000 miles on it. CV joint boots appear to be OK as there isn't any leakage evident. A few days before this happened, my son asked me to take a look at the car as there was a new sound and it seemed to be getting worse. It seemed to be coming from the tranny. It changed pitch with speed and I could feel a slight vibration on the gear selector (stick) as well. The noise and the vibration would go away if you let off of the gas though.

I checked the ATF and it is at the proper level and looks OK on the dipstick and paper towel. I also checked the level of the lube in the differential and it looked good as well.

We were going to take it to a tranny shop and have it checked out. but the next time the car was driven, the axle came out part way. She was turning a corner and all of sudden the little noise got VERY BIG.

Ideas ? Commments ? Suggestions ?

[1 Lucky Texan]

someone working on the car in the past (maybe struts, bearing, likely axle replacement) didn't seat the stub into the diff or the stub is missing its circlip to retain it.

if you're lucky, the seal is OK. I'd consider changing the diff fluid, reseating the axle stub and hope no serious damage was done.

it is uncommon and I have only read of it a coupla times in the past.

[cardoc]

The axle came out? It didn't separate at the joint or brake? It can brake and leave an intact boot.

If it came out, I'd say it wasn't locked in the differential to start with or the drift pin was left out. Both would be due to previous repairs and the tech erred. If it is broken or came apart at the joint, it's not unheard of.

I would also be looking into loose ball joints or lower control arm bushings. Something in the suspension allowed for the extra extension needed for the axle to come out or separate.

[skipatroller]

Hey, I just want to let folks know that the axle was indeed partially out of the differential and they had to replace the stub shaft as the end of the splines were messed up. C-Clip was still on it. CV joints seem fine. Ball Joints and the rest of the suspension seem fine so they are a bit perplexed as to why and how the axle would come out. Right now their only answer is that maybe it was worked on previously and it did not get put back together all of the way (ends of the splines finally wore enough to let it start slipping).

The issue is that now that they have it back together, they have noticed a noise, but are unsure of what is causing it, so they are still trying to diagnose it.

[skipatroller]

Just got the call. They suspect something is broke inside of the front differential as in addition to the noise the front differential is wantiing to lock-up. They are saying the most cost effective action is to replace with a used (70k mile) transmission and differential. Looking at a $1200 to $1300 bill. Ouch ! !

[CNY_Dave]

I just replaced my trans because of a worn pinion bearing.

Make sure they don't swap in a 2004 trans. The Hollander Interchange information has been updated that it won't work in an '03, but not everyone uses it.

The labor for the swap should be 'about' 600-650, my trans was 800 but it was for an H6, a little rarer so a little more expensive.

Outbacks and legacies have different gear ratios in the diff, hopefully they know to use a 4.44 geared trans, not a 4.11 from a legacy.

[Boxxerace]

What is this, the third exploded differential this week? (possible)

Here's my thread on my rear diff, but it gives you an idea of what might have gone wrong. cv joint popped out and wont go back in (spring retainer style joints)

Call and source a used transmission yourself if you have the time or check for cars being parted to maybe save some coin. That said, your mechanic might have much better sources and might look out for you better than your own judgement.

Sorry to hear about the failure!

[Boxxerace]

Originally Posted by CNY_Dave

Outbacks and legacies have different gear ratios in the diff, hopefully they know to use a 4.44 geared trans, not a 4.11 from a legacy.

Note: Better check the gearing in person than the spec book as Dave points out. In my Outback, I have 4.11 gears, counter to Dave's experience.

[CNY_Dave]

2000-2004 with 4.11, or your 2005?

For Gen 2 it's 'supposed to be' 4.44 for H4 OB with 4EAT, 4.11 for legacy and H6 OB.

I have no idea if they kept to that for '05+.

[Boxxerace]

The 04 actually. I am not sure why but the ring gear stamp does not lie.