RS4 Diff grinding noise..........Help

[samaj]

My 2001 RS4 has this grinding noise while driving. Seemed to come from the bottom.

Current mileage is 160,000 KM. Engine is healthy. Two new OE spec Turbo installed about 10,000 km ago. Gear changes were smooth.

Opened up the diff & saw these small metal shavings.

[samaj]

Ok some update pics .


Been told by the garage that the diff is bust. But the top silver gear on the diff. looks as good as new.
Notice the wear on the ring pinion?
Any observations, suggestions?

[themadscientist]

It's toast. You'll want to open it up and see if any bearings failed, especially the pinion thrust.

[samaj]

Open the diff or the gearbox?

[MacDaddy]

Hard to say without better pics of the ring and pinion. Wear on the ring gear looked ok, but looks like a chunk is Missing off the pinion?

Given your climate I would probably be running some fairly thick gear oil in there, maybe even a single weight gear oil since your temperatures stay fairly consistent year round. I'm willing to bet lack of maintenance/too thin an oil is the culprit or a very contributing factor. These diffs aren't known to fail.

[samaj]

Some close up of the open diff housing.
The gearbox is yet to be opened.

Have a look here the gears ,diff. Can someone spot anything that's broken, worn out more than normal?

[Scotty@Advanced]

It's not entirely uncommon to see ring and pinion failure on the 01E transmissions with the pump. This is because the oil lines leak and nobody ever checks or changes the trans fluid level. You will need a complete teardown to clean all the debris out of the gearbox and probably have to replace the synchros as metal fragments tend to embed themselves in the rings. Of course you will need to replace the ring and pinion, and possibly the pinion bearing as those parts are the first to go when oil starvation is an issue. I've seen this on a number of Allroads as well as the diesel gearboxes with the pump. Hit me up if you want a custom gearbox build.

[samaj]

Thanks Scott.

Yes I would be interested in a rebuild trans & gearbox with new bits like pinion & drown gear, bearings , seals, new synchros installed.
Please PM me the related costs & shipping to Dubai at your earliest.

Cheers

Sam

[Lanorg]

Was the grinding noise apparent when rolling in a straight line vs turning? Or on throttle straight vs a corner?

I have a noise that develops when cornering only with my BBS 18" CH wheels but not my SSR 17"

[samaj]

It was a running noise. I could feel how smooth the engine was. But this defo was a gearbox/diff type of a grinding noise from bottom.

[samaj]

Hey Scott....waiting for your quote.

Thanks

[samaj]

Scott

Pls send me your quote.

[Mille Bornes]

You could contact him. He lists his number in his signature, and I'm sure his email is on his site...