RE: Model 205

That's an interesting development, but "'This is something that hasn’t been done on a truck before,'” says Frank Metelues, design engineer for Dana’s Automotive Systems Group, referring to the manufacturing of an integrated tube into the axle body by die cast process." is a bit scary to me. Cast products are so much more prone to failure. Hopefully they're using some trick alloy to counter the inherent frailty of casting.

It an IFS front differential, so the axle tubes will never see suspension loads. The worst load possible (other than binging up the drivetrain hard) would be drooping a cv shaft past maximum angle. The differential and axle housing won't see any kind of impact from jumping, or any other bad driving (unless you actually damage something so it pushes into the housing).

I think an all cast housing for an IFS diff is well... inconsequential, if they're going to use something with non standard gears, might as well be able to produce it for $2/truck less

I've seen a handful of Liberty aluminum IFS diffs bust under less-than-severe use...

did they break from impact or over torque?

Don't recall, but I have a vague feeling it was load, not impact...

Drip, you're correct, but the housing will endure some torsional and thrust loads. Naturally those can be engineered for, so hopefully that has been done correctly.

Personally I'd rather have my stuff beefy (and proven) rather than save 35 pounds. But that's just me.

quote:

Personally I'd rather have my stuff beefy (and proven) rather than save 35 pounds. But that's just me.

More weight on a solid axle will also lower your center of gravity.