ramblinChet
Well-known member
Is the 'failure of AEV differential cover' the loose bolts you described back in your post #614 or is/was there another issue? I was getting ready to buy the front one, and you certainly have given them a real world test, so a very good source for a testimonial (good or bad).
You are correct - the design failure I am speaking of is the unexpected loosening of the bolts securing the AEV differential cover to the axle. Following a lifetime of working in the military aviation and space industries along with a significant dose of automation and robotics one thing I can say for certain is that I read all manufacturers instructions and install a component using premium tooling. In this case my torque wrench had only been used twice since it had been calibrated at a NIST traceable ISO 17025 metrology laboratory.
What is most disappointing is that AEV spent more time and effort discussing how to properly apply the sticker compared to anything else. Of course, a differential cover installation is a simple event but the key point to remember here is that the AEV covers are very thick nodular iron and weight maybe ten times what the stock covers weigh. With that in mind, maybe using the stock fastening method and values would not be sufficient.
I am pretty certain AEV never performed any significant testing on the covers regarding is they remain in place while being exposed to hundreds of thousands of miles of rough terrain. My front and rear differential covers became loose and the front was loose enough that it permitted water to enter while still retaining all the differential oil - I discussed this with AEV and the person I spoke with was entirely unable to understand the significant difference in viscosity between water and 80W-140 gear dope and how a seal may permit water to leak in but not permit heavy gear dope to leak out.
In the end, I am out around $2,000 to replace the front differential, gears, and bearings, and AEV states they have nothing to do with it. The technician I spoke with at AEV danced around in circles, changed his story, and generally left me wondering if AEV has been bought by another investment group and is not being managed and directed by them. The customer service is certainly not the same as it was years ago.
I still think the AEV differential covers are the finest available but with one caveat - you must check them regularly to verify the bolts have not come loose. To me, this is a design failure since when was the last time you have been required to check the bolts on your OEM differential covers?
For reference - see the attached AEV instructions which are poorly written and conflict with themselves and each other.