My Diff Cover.. Hmmm...

bvstone1 · 06-10-2004, 07:27 AM

After reading the thread on the diff covers, I thought I'd take a pic of mine. I expected it to be fine, but I see a little oil around some of the bolts. A little rust on top, but that looks to be coming off the clip for the brake line that's up there.

I've towed a 8foot sled trailer with 2 ATVs on it a couple times, and hauled a half yard of rock once for about 15 miles... I have about 2000 miles total.

What's the concensous here?

BigJoe_Titan · 06-10-2004, 07:33 AM

I would take it in to the dealership to make sure it is not leaking due to the wet spots around the cover. If they have to take diff cover off and reseal it, it will have to be drained and new diff fluid.

37L1 · 06-10-2004, 09:44 AM

Here's what I'd do.

Wipe off the grease/lube/dirt. Watch to see if any new leakage appears after driving a few days. Check the lube level add/change as needed. Find out why you are getting the rust and try to prevent it if possible. Take to dealer and have the tech inspect if you are unsure of what you should do.

Good luck,

37L1

**CaliforniaTitan** · 06-10-2004, 09:49 AM

Agree with 37L1....the light rust I see there is surface rust from where those attatchments are for the lines on the top. The fluid on the bottom though could be a slight leak. I would have service look at it and maybe get them to replace the seal. IF they do, make sure they put enough diff fluid back in.

Chris

bvstone1 · 06-10-2004, 01:01 PM

Thanks. The leaking on the bottom, and on the top right is what got me thinking. I'll have to make time to go check the level this afternoon... (swamped today for some reason!). And maybe tommorow morning I'll run it by to show the techs..

bestatchess · 06-10-2004, 01:43 PM

The leaking around the bolt holes is typically indicative that they overtightened the bolts on installation (or improperly applied the RTV sealant). Paradoxically, if you over-tighten the bolts holding two flanges separated by a bead of sealant, you will squeeze out the sealant, resulting in leakage. In other words, if you tighten to the correct extent you will get a good seal, tighten further you will get leaks.

I would go buy some Mobil 1 75-90 (or the conventional gear oil if you like that better) and the appropriate high temp. RTV sealant for the diff cover and Permatex thread sealant for the drain & fill plugs. Then I would drain the oil, take the cover off, clean off the old RTV on the diff and cover (you might want to use a stiff scrub brush & some solvent for this, being careful not to contaminate the gears with crap) (and also wipe out any crap you find inside the diff), apply a new bead of RTV around the edge of the cover and around the bolt holes, and then put the cover back on, being careful not to over-tighten the bolts and thus squeeze all of the new RTV out, (which would result in leaks of the type you have now). Then I would fill it with the Mobil 1. I would also inspect for (and file off if necessary) any unusual projections on the inner periphery of the diff cover that might be causing the leaks.

I was hoping to put that off until somebody made a high capacity cover, but I may end up taking the cover off next time I change the diff oil so that I can trace it and send it to after-market cover mfgs.

BigJoe_Titan · 06-10-2004, 01:58 PM

bestatchess,
It only has 2000 miles on it, it is still under warranty. Why should he fix their mistake. Take it in, have them repair, then drain and refill with mobile 1.

Stitch · 06-10-2004, 02:01 PM

You should check the fluid level just to be safe but other than that I would not worry about the stains.

The road grime will act like a wick and draws the fluid out, so the slightest seepage looks worse than it is. All spots combined that's probably 1/3 of a drop.

If you're really bored someday and you felt like changing the diff fluid then pull the cover off also.

You'll need to really clean the cover, flange , bolts and thread holes squeeky clean, use brake cleaner or the like. See if there is a gasket available and then use something like Permatex Ultra Black RTV. That should seal it up.

bestatchess · 06-10-2004, 02:17 PM

Quote:

Originally Posted by BigJoe_Titan

bestatchess,
It only has 2000 miles on it, it is still under warranty. Why should he fix their mistake. Take it in, have them repair, then drain and refill with mobile 1.

You have a good point. I just have an abiding and fundamental distrust of dealers as a result of many years of abuse (although my current dealer has been peachy thus far).

bvstone1 · 06-10-2004, 04:01 PM

Ya, I am going to have them look at it, but that's it. I'm not going to do anything like that while it's under warrenty. I imagine with the service I have received so far they'll get it right in to get looked at, and most likely do what you explained. Hopefully.

Austin · 06-12-2004, 08:23 AM

I took a couple pics of mine before it got dirty -