balls fell out , again !

scesnick · Mar 31, 2007

I have been having an ongoing problem with my 200bd 4wd system. I have a front pinion gear that is stripped. Well, I HAD to fix my road because of spring errosion, so, I put it back together with the worn gear but did not use the 4wd. It runs fine in 2wd. I used it for maybe 3-4 hours and darned if the balls didn't fall out of my drive shaft again !! and i wasn't even in 4wd. I have no idea why. The best I can figure is that the 2 springs on the rear of the differential is getting weak and allowing the shaft to move a little too much.

Any other ideas???

mark777 · Mar 31, 2007

scesnick said:
........ The best I can figure is that the 2 springs on the rear of the differential is getting weak and allowing the shaft to move a little too much.

Any other ideas???

Scesnick, I've done my fair share on different models and I think it just has to be spring pressure on the shaft.

It takes quite a bit of effort to pre-load the springs, washer and pin. I have to use both hands to slide the spring assembly back, lock it down with needle nose Vicegrips (that works great) and gently align and release the 'grips'.

IMHO - There would have to be extensive damage and missing material at the end of you pinion gear at the ball pockets to Not hold the shaft assembly in place.

Mark

kenmac · Mar 31, 2007

make sure that you have all the parts . I think there is a drive pin through the drive shaft then a washer then the spring. Mabe the spring has lost tension to keep your balls from falling out. I'am glad my balls don't fall out, there too much trouble to put back !

Ductape · Mar 31, 2007

I'd just like to add that my balls have never fallen out either....... though i have taken them out intentionally a couple times. I hope you do get your shaft straightened out !