Diff leaking after gear install - JKowners.com : Jeep Wrangler JK Forum
 
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post #1 of 9 Old 12-27-2009, 10:50 AM Thread Starter
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Diff leaking after gear install

About 4 months ago I had 5.13s replace my 4.10s... Ever since that was done my front diff leaks. I have Solid diff covers that have been used with no problems for 2 years with the 4.10s. The threading in the axle part of the diff was bad in some places so I had it re- threaded at the time of the install. They rethreaded some of the rear diff threads as well. The rear does not leak. The front was leaking... A puddle about 5" wide after every drive on the Jeep. I had the guy that installed the diff and gears re- do it but got identical results. Than I did resealed the diff with the same results. Now Firestone replaced the front diff fluid by removing the diff and it is leaking again. Had firestone do it again with identical results. I can keep going back to firestone and getting this fixed under their warranty but it's too much of a headache... I need a solution! ... any suggestions? I'm thinking of buying a new diff cover just to test it out but I can't really see that helping.

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post #2 of 9 Old 12-27-2009, 11:08 AM
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Is it leaking from the cover area itself? Not the pinion seal (where it meets the driveshaft) and dripping down? How about the drain plug in the axle, is that leaking? I'd say the cover may be warped, without a true flat surface to test it on, it's hard to tell, or you could try a lube locker gasket on the diff cover and see if it helps.

Pretty much three areas to take a look at. Pinion seal leaking and running down. Drain plug leaking (teflon tape?). Or the actual diff cover being warped. With that cover being on and off so many times and not fixing it sounds like it'd be warped. A gasket could help seal some inperfections in that, also the RTV used may not be allowed to setup the proper amount of time before its filled and run.

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post #3 of 9 Old 12-27-2009, 11:19 AM Thread Starter
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All great points... I checked all that out and rerouted the breather to the back of the jk so that oil won't confuse me as firestone overfills the diffs. It's def. Leaking through the bottom of the rtv on the cover. Never figured a steel, bulletproof Solid diff cover could be warped... I guess I'll be ordering a new cover to try that out.

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post #4 of 9 Old 12-27-2009, 11:39 AM
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It would be very tough to have a warped cover as well! It'd be wise to check for any cracks in the housing or cover from possible over torquing. Could RTV the bolts for the heck of it. Really limits you on paying someone do keep popping this cover on and off. If it was my JK in this situation I would;

*Drain and remove the front cover.
*Clean off mating surfaces and clean bolt holes.
*Using either a lube locker gasket, or "right stuff" rtv (in a cheese can) apply RTV to the axle housing.
*Apply a small amount of rtv to the bolts on the bottom half of the axle (now this shouldn't be necessary since they don't go into the oil. However there could be a hairline crack somewhere allowing fluid out...stranger things have happened)
*Install cover and step torque bolts in a crossing pattern (install all 'hand tight', torque all in a cross patten at 10ft/lb, 15ft/lb, 20ft/lb, to proper spec).

Let it cure for 20 mins (or whatever is on the bottle of rtv) and fill. If that sucker isn't sealed then there is a problem with a cracked housing, or really tweaked cover.

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post #5 of 9 Old 12-27-2009, 12:03 PM
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GET those resuable gaskets from quadratec or wherever. they are sooooo worth the extra cash
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post #6 of 9 Old 12-27-2009, 02:12 PM
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Quote:
Originally Posted by Goodysgotacuda View Post
or you could try a lube locker gasket on the diff cover and see if it helps.
I have not any good things to report with the Solid covers AND lube lockers. They sucked, In my case anyways.

Always leaked, Bolts always backed out and never stayed tight.

I use RTV now and all is good.
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post #7 of 9 Old 12-27-2009, 02:29 PM
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Quote:
Originally Posted by Big A View Post
I have not any good things to report with the Solid covers AND lube lockers. They sucked, In my case anyways.

Always leaked, Bolts always backed out and never stayed tight.

I use RTV now and all is good.
Of all the issues I had with the Solids, they never leaked with the Lube Lockers.

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post #8 of 9 Old 12-27-2009, 03:15 PM
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Sounds like lack of consistency in the Quality, Or lack their of.
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post #9 of 9 Old 12-27-2009, 03:20 PM
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Quote:
Originally Posted by usmcdoc14 View Post
GET those resuable gaskets from quadratec or wherever. they are sooooo worth the extra cash
You mean these

http://www.trailduty.com/index.php?manufacturers_id=98

I had a RockCrusher (now Solid) cover and the metal was porous in one place and it leaked a little, but barely enough to notice.

Check the mounting surfaces at the bottom, it's quite common for the bottom edge to get ground up sliding over rocks. I usually take a file to the bottom outer edge of the mounting surfaces of the diff cover and the housing whenever I have the diff cover off.

It would have to be pretty warped for RTV not to seal it well.

You say they re-thread some of the bolt holes, did they use heli coils or re-thread them for a larger bolt? If for a larger bolt, look at the bolt heads and make sure they are seating correctly against the flange surface.
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