Leaking rear diff - advices ? - Defender Source
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  #1  
Old December 2nd, 2009, 07:24 AM
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Julien Dalbin
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Leaking rear diff - advices ?

I think there is no doubt about the failure of the seal, but
i'm curious, i checked the oil level and the diff was way
overfilled. Is it possible the excess of oil caused the "premature"
failure of the seal ?
I know, i have to check the breather line for blockage.

Any advice for the seal replacing ?

Oh, almost forgot, it's on a 04 D2.
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  #2  
Old December 2nd, 2009, 07:28 AM
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It's very hard to overfill the diff unless the truck is parked on a steep slope with the fill plug pointed skyward.

Just to confirm, the leak is coming from the area of the pinion? I ask because my rear diff leaked like a sieve and it just needed to have the third dropped, cleaned up the old seal and resealed it. No more leaks.
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Old December 2nd, 2009, 07:36 AM
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Leaking Pinion seal

Just finished this job. Appears from your photos that the rear pinion seal is leaking. You can replace the seal but often times due to the forward facing surfaces the differential housing presents, mud, grit etc. finds its way to the output flange surface the seal rides on. You may want to check this surface when replacing the seal. Solutions include speedy sleevs or just polishing any irregularities out of the surface of the flange for more uniform contact of the seal.
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  #4  
Old December 2nd, 2009, 08:27 AM
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Quote:
Originally Posted by JFD
I think there is no doubt about the failure of the seal, but
i'm curious, i checked the oil level and the diff was way
overfilled. Is it possible the excess of oil caused the "premature"
failure of the seal ?
I know, i have to check the breather line for blockage.

Any advice for the seal replacing ?

Oh, almost forgot, it's on a 04 D2.
Pull the drive shaft and large nut, pry out seal and thats pretty much it. I think your over filled problem could be 2 things, either someone pumped in to much oil, at a place like jiffy lube, or perhaps you have gotten some water in there. Did the oil look milky?
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Old December 2nd, 2009, 08:33 AM
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Julien Dalbin
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I was surprised myself of the overfill, Stu is right, it's not
easy to overfill a diff. The good thing is the oil was clean,
no signs of water contamination.
I'm going to clean everything, but as i'm under it, all
greasy and happy, i guess i change the seal also .
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Old December 2nd, 2009, 11:28 AM
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Breather

I should also add that critical to the normal operation of the rear drive unit is to have good ventalation. Basically, although the Breather seems a trivial part, it's essential that it works to dispell the hot air/gases created as the rear drive warms up. Needless to say, if there's no place for expanded air to go, something gives. You could have also created an unusual hydraulic condition with the over fill that would intensify air expansion or pressure in the drive. Wouldnt be the first time I've seen a seal go south that way.

If it's just an over fill and the condition came suddenly after a servicing, you could experiment and just clean everything up, check your breather is working properly and then put some miles on it to see if anything is leaking from actual wear before taking steps to surgically removing the seal.

Again, if you do have to replace the seal, may not be a bad idea to check the drive flange outer surface (mating surface to the seal). If it's at all grooved or pitted, it will leak again soon. Any competent machine shop can polish out small imperfections to within tolerance.
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  #7  
Old December 2nd, 2009, 06:03 PM
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I know nothing about a DII but I overfill my diffs (to run wet hubs) and they don't leak.

As long as the breathers are clear, overfilling, within reason, should not cause any leaks.
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Old December 2nd, 2009, 07:26 PM
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How much shows up on the driveway and over what period of time? My truck has some slight weeping in the pinion seal but it only produces a few drops of oil over night. I think it would take a lot more oil loss for me to tear into it and replace it, I can tolerate a bit of oil on the driveway.
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  #9  
Old December 2nd, 2009, 10:56 PM
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Julien Dalbin
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Nothing on the driveway yet, so far it's only on the diff
housing.
I bought the seal from stealership, fair price, 17$.
I'll clean the whole thing this week end and take a
good look at it.

Thanks guys for inputs
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Old December 2nd, 2009, 11:23 PM
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Quote:
Originally Posted by JFD
Nothing on the driveway yet, so far it's only on the diff
housing.
I bought the seal from stealership, fair price, 17$.
I'll clean the whole thing this week end and take a
good look at it.

Thanks guys for inputs
That aint too bad. Good luck with it and keep us informed.
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  #11  
Old December 7th, 2009, 07:30 AM
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Julien Dalbin
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Cleaned the whole thing this week end, just to check if
it will keep leaking, i hope it won't.
I removed the rotoflex, so i could have a better access
and i realized that if i wanted to go any further the
centralizing peg is not that easy to remove, i'll make
a extractor for it this week, just in case.
As i was under the truck, i changed the fluid in the
rear diff, put some Motul synthetic gear 300 (75w90)
and greased the rear prop shaft and ujoint, they took
half a can of grease ...
The breather line is free, or least as free as it can be,
because it does offer a little resistance when you blow
in it, i guess it's because of the lenght and small diameter
of the line.
What about the big dead weight attached to the rear diff,
i mean this thing is obnoxious, is it really indispensable ?

Cheers
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