TeraFlex Plus Re-Gear Problems....

[Carolyn]

Some of you may remember I re-geared my 2011 (auto) JKU to 4.88's and added ARB lockers up front (already had lsd in the rear) at TeraFlex Plus. Yes, I properly broke the new gears in, then had them change out the gear oil.

About 3 months later, and a couple of states away (had it done at TeraFlex Plus in Murray, Utah. Am now in north county San Diego, CA until the fall...) I'm hearing a whirring noise. Took it to my mechanic, who diagnosed at least pinion gear bearings are shot. The rear diff fluid was FULL of metal shavings... He recommended I take it to Jerry at Oceanside Driveline.

When the folks at TeraFlex Plus did the re-gear, they chose to not instal new pinion gear bearings, stating mine were perfect.

3 mechanics have now told me that there is only one reason for my bearings to fail this soon. There are two ways to set up a re-gear.
1) Using new bearings -
2) Re-using the original bearings.
In the second case, the bearings can not be tightened as much as if they were new. And so - they must have set the system up as if they used all new parts, tightening them too much.

Now, my jeep is at Oceanside Driveline... and apart. The front is good.
The rear is thrashed, including the ring and pinion gears, all bearings, the lsd is chewed up and carrier bearings too. The entire rear end is having to be rebuilt. Ouch!
Driving it back to Utah was not an option. Too far. Too much damage already. Wouldn't have made it

I put a couple of calls in to one of the service fellows, to let them know the predicament I'm in, and get specifics on the re-gear (double checking my facts). I've emailed TeraFlex Plus (Dennis Wood is the service manager) yesterday. And I've sending a hard copy letter today. Haven't heard anything from the email as yet...

Will keep you posted as to the outcome.
__________________
Carolyn

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[HillbillyfromAL]

Keep all the receipts and if it was under warranty see if they will reimburse you for the parts. Next time have the shop use all new parts. Bearings aren't meant to be pulled and swapped, even though plenty of places will do it to save you a little money it'll usually end up costing you more in the long run. Think of it like changing the oil but not the filter, you just created a fail point.

[Carolyn]

Yes..... I have ALL my receipts.... and the shop in CA is putting in ALL new parts. Because they have to. Everything inside is toast. Well, shredded and scarred... I only had their advice/recommendation to go on. I should have done more homework and asked more questions. Hind sight is 20/20 and all that.

[HillbillyfromAL]

Well live an & learn at least it didn't grenade on you while cruising on the highway.

[brianjwilson]

Wow, every shop I've had re-gear one of my rigs told me that they will not re-gear unless all of the bearings are replaced. Just for that reason. Why on earth would you re-use the pinion bearing when you've already got it all apart? When you're spending a couple grand on gears and lockers it is silly to leave out a pinion bearing to save a buck. Sorry about your luck, hopefully they'll help with reimbursement.

[Carolyn]

In hind sight.... I am surprised they didn't use new bearings. I pick it up today.... and will see how many miles were on the odo at time of install....

I mailed the hard copy letter to Dennis at TeraFlex Plus yesterday.

[TeraFlex]

In hind sight.... I am surprised they didn't use new bearings. I pick it up today.... and will see how many miles were on the odo at time of install....

I mailed the hard copy letter to Dennis at TeraFlex Plus yesterday.

FYI Dennis is out of the country for 3 weeks. We will watch for your letter and get it to Ben Falkner who is over the shop and not Dennis.

[Carolyn]

Thank you for your response, and no, I did not know Dennis is gone. I mailed it yesterday (to the Murray TF Plus) addressed to Dennis.

As things will go, it is not finished today. I won't be able to pick it up now until Monday or Tuesday.

Again, thank you for your help in this matter.

[Carolyn]

OK.... update. These guys are seriously *on it*. I was contacted today, and I'm impressed.

Just wish I had my jeep back.... had to cancel a shoot in Mexico - C'est la vi.

Thanks all.

[brianjwilson]

Good to hear they are making contact with you. Good luck!