Rear fluid dripping

[Plati]

I'm not even sure what the right question is, but … I've got fluid on the driveway, small amounts. Rear of 2003 XLT 4x4. Looked underneath and see this picture, not even sure what part that is … rear differential? Anyway looks like a gasket is broken out of bottom and dark fluid so this is probably it. Did the gasket just degrade and die? Do I just take the cover off and put in a new gasket with the appropriate fluid? Hasn't been too much or too long so I hope its not damaged other than gasket. Any advice appreciated. Will she live for another year?

 

[Vancouver Bob]

Yes that's your rear diff. I don't know how easily the cover comes off since it ties into the chassis.

 

[Plati]

Yes, starting to see now. How much labor to get that out & put it back on? It looks like maybe if its out on a table you can replace that gasket?

The game might be (for now) … check the fluid level and see how low it is and top it off then run it and see how fast it loses fluid. Hope that I can drive it for another year. Maybe put some JB weld there to slow down a leak. Cob job! What sealant or adhesive might be best suited for trying to seal that up? Anybody have any knowledge with that? I know there are some great products out there! I think I'll see if I can drive that errant gasket back in there a bit, maybe pack it with dental floss or something like chinking. I might be able to put some small c clamps on that area with a rubber mat to hold the goo on. Its gonna be ugly. I would consider welding it but too close to fuel tank.

Maybe try something like AT-205 if I have nothing to lose?

Its a low mileage second vehicle, mainly a winter beater. I might be able to nurse another year or so out of it. Only drive it locally.

Would like to fix it. If I can fix it for $500 I'll probably do it but not putting much money into this rusted out hulk!

 

[Hamfisted]

Have you gone through checking the torque on the bolts to make sure none of the bottom half are loose? Make sure you use 75w-140 gear lube, and check it on a regular basis. The fill plug is on the front driver's side of the differential. Spray the area with some brake cleaner and see if you can isolate where it's actually leaking from. It's more common for the shaft seals to leak than the gasket itself.

 

[Plati]

Not yet, but I will. On a trip now so that will have to wait until May. The gasket is clearly broken and separated and sticking out with oil drops right there so that was the quick conclusion I came to. Thanks. I'll keep an open mind.

 

[Trainmaster]

If it's leaking slow enough that you could clean it up really well with brake cleaner and get some silicone sealer to set up in it before it leaks down, that might work.

Then, of course there's the right way...

Whatever you do, don't pull out the drain plug untill you know you can get out the fill plug. Guess how I know that...

 

[CaptOchs]

Mine started leaking bad a week before a camping trip. I had just put the camper in the driveway when I noticed it. As it turns out it's no easy fix as the axle had to be dropped. It was somewhere around $900-1000 in parts and labor.

 

[Plati]

Have you gone through checking the torque on the bolts to make sure none of the bottom half are loose? Make sure you use 75w-140 gear lube, and check it on a regular basis. The fill plug is on the front driver's side of the differential. Spray the area with some brake cleaner and see if you can isolate where it's actually leaking from. It's more common for the shaft seals to leak than the gasket itself.

MrHamFist -->Thanks for the good advice. I finally got around to it (been travelling a lot). First I scrubbed the whole region then drenched it with brake cleaner multiple times. Got it cleaned up pretty good. Drove it (had to be at speed) for 40 miles and found the leak source. Yes, at first I thought it was the cover but NO it's where the shaft comes out the side. Now I need to see how much effort it is to fix that seal … or maybe (due to old age of the TRUCK, being one step away from the junkyard) I'll just monitor it and refill every once in a while? I only do about 4K miles per year on this beater. I topped it off and it was down about a pint.

Does anyone want to help me out with any estimate of the effort (or co$t) to repair that seal OR is there any other alternative? Put pepper in with the fluid?

 

[TomB985]

I just pulled this from a TSB listed on AllData, and I think you lucked out.

2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear
Axle Stub Shaft Seal.
Includes Time To Remove
and Install Halfshaft. Both
Sides. This Labor
Operation Can Be Claimed
With A, B, Or C (Do Not
Use With 4139A, 4139A2)

Keep in mind this is warranty time, customer pay is usually a good 30 or 40% more. But plan on two hours of labor plus the part cost, which is under $10 from rock auto. You probably have this fixed for $300 or less. FYI the differential covers seal is 3.2 hours book labor to replace.

 

[Hamfisted]

Yeah if you have a PepBoys shop in your area they charge $300 to replace the seal. I would guess other shops are about the same.

 

[Plati]

Hmmmm… yes I see what looks like a later TSB
http://ww2.justanswer.com/uploads/kennyz1963/2008-07-16_200342_tsb06-22-05.pdf

I'm kinda slow, not sure why I lucked out other than to find the TSB with new seal AND its not the cover its the shaft seal. So, I got that goin for me - which is nice. At first I thought it was going to be a free recall.

I guess I should take it to Dealer and get quote to have that done. Best not to leak as leaks usually get worse not better. In the meantime I can drive and monitor I guess. Its pretty old and its a Rustbucket so I have some concern that things will go south as soon as you put a wrench on it to disassemble. Looks like wheels and brakes need to come off which means a sledgehammer to the rotors = new rotors and pads. Rustbucket!!

I think I'll rip a long strip from a white tshirt (if I can find one) and wrap it around the seal. That's way I can capture the leaked fluid to monitor the loss rate. Otherwise it would just drip on the road, mostly.

I often wonder how long I can keep this BEAST on the road.
I'll spend $800 a year on repair and that's IT

 

[Hamfisted]

If your rotors are hard to remove try this method to press them off ....

 

[TomB985]

Hmmmm… yes I see what looks like a later TSB
http://ww2.justanswer.com/uploads/kennyz1963/2008-07-16_200342_tsb06-22-05.pdf

I'm kinda slow, not sure why I lucked out other than to find the TSB with new seal AND its not the cover its the shaft seal. So, I got that goin for me - which is nice. At first I thought it was going to be a free recall.

It's not that you're slow, I just wasn't very clear.

You're talking a labor difference of two hours between the rear cover gasket and the axle shaft seal. So depending upon your labor rate, this will cost you between $2-300 less because of that. It's a TSB, not a recall, so no free repair… But a few hundred dollars less out of your pocket is how you lucked out.