HELP: Massive Diff Leak - Fluid spraying out

[BrandonF]

So, I installed a used elocker rear axle on Friday. It seemed to be in good condition and was out of a 1997 with only 100 000 miles.

After I installed it, I drove it home no problems. Later that evening, I went to my 4runner and noticed a puddle of diff oil below the 3rd member and it looked to be coming from the elocker motor area. At this point, the breather fitting was just an open nipple, so I figured that I had just overfilled the diff and it was leaking out of this open breather. So, I extended the breather up to the gas filler neck.

Today, I drove approximately 200 miles, stopped at a gas station, and noticed a TON of diff oil dripping on the ground below the 4runner. I looked underneath and found that the entire rear end was covered in oil, including the spare tire and even the rear window and lift gate. Underneath, it is mostly on the driver's side of the axle and again, it appears to be coming from the elocker motor area. However, I checked the end of the elocker breather hose I installed and it is clean and dry. No leaks coming from it.

Can anyone explain this? There is a definite correlation between my speed and the leaking. If the vehicle is sitting, it doesn't leak a drop. However, from those 200 miles of highway driving, I lost nearly 1.5 litres of diff fluid! Yes, I realize was on my way to running it dry. With city driving, it leaks, but it doesn't seem as bad as the highway driving. I cannot see any obvious crack or hole where it is leaking from, but given the seriousness of the leaking, it's as if oil is spraying out of my diff as I drive!

I haven't wired up the elocker yet, so it is just fixed in the open position. I don't see how this could create any leaking though.

 

[BrandonF]

BUMP

Nearly 100 Views and no one has any input?

One thing I can think of: I removed and checked the main breather fitting for blockage when I installed the diff, but I did not check the E-locker breather. I simply installed a hose to the fitting. I will check this today. If this is clogged, maybe it could be causing pressure build up?

This is just the strangest leak. It is leaking out of the top of the elocker motor area, and like I mentioned in the first post, it only happens when driving. Is it normal for there to be SOME pressure build up in the differential when it is running? Or should it be completely even with the atmospheric pressure?

There is either some serious pressure build up going on, or the oil is simply being sprayed up at the top of the inside of the differential by the gears rotating with enough force that it is finding it's way out of the top of the differential.

Another thought I have: When I got the differential, I cleaned it up with a wire wheel before painting it. I was careful to avoid the gaskets, but is it possible I could have nicked one of the gaskets enough to damage it and cause a leak?

 

[BrianSD_42]

Either the axel is bad or your bearings and seals are bad.

 

[GVL]

Hang in there bud, I noticed a lot of slow responses over the holiday weekend.

Sorry if I missed it, but did you extend the breather already or is fluid coming out of the breather valve on the casing? Have you tried touching the differential casing after driving to see if you feel anything unusually hot? This may help determine if it's a pressure issue or just spraying somehow..

A couple pics are worth a million words to a lot of guys here. I had a similar issue once and the problem was noticed to be completely different from what I was just assuming it was.

 

[JRZEE2000TR4LTD]

It is normal for pressure build up hence the reason for the breather. Did you replace the gaskets and or seals when you replaced it and if not why not? If you got it out, I would replace every seal and gasket that I disturbed. To find the leak, clean it up real good with some brake clean. That stuff leaves a dry finish. Take the truck for a quick, brisk drive. May only need to take it down the street. Don't go far. If you have to, pull over and crawl underneath to see where it's coming from before the oil gets everywhere and you won't be able to see where it's coming from. Good Luck!

 

[squabeggz]

Stupid question, but did you use new gaskets? Even if you didn't nick one on the clean up, they may be bad even if they look good. It's always a good idea to replace gaskets anytime you take something apart that relys on them for a seal. Just a thought. Hope you get it sealed up.

 

[BrandonF]

Either the axel is bad or your bearings and seals are bad.

Which bearings and seals would you be referring to? I am not clear on how bad bearings could cause a leak like this. I've done some googling, but I'm not very familiar with exactly how the elocker part of the differential works

 

[BrandonF]

Hang in there bud, I noticed a lot of slow responses over the holiday weekend.

Sorry if I missed it, but did you extend the breather already or is fluid coming out of the breather valve on the casing? Have you tried touching the differential casing after driving to see if you feel anything unusually hot? This may help determine if it's a pressure issue or just spraying somehow..

A couple pics are worth a million words to a lot of guys here. I had a similar issue once and the problem was noticed to be completely different from what I was just assuming it was.

I extended both breathers. I checked the ends of them and they are clean and dry.

I felt the diff and it was quite hot. I compared it to the transmission and transfer case and they felt close to the same temperature. The diff did seem a bit hotter though. It's hard to tell just by feel. I also have experience with all sorts of large industrial gearboxes at work and combined with that knowledge, my diff doesnt seem unusually hot. If the diff is running hot but the breathers are functioning properly, I feel like it shouldn't leak like this anyways. Am I correct? Regardless, I will check the elocker breather nipple tonight, as I DID NOT check that to see if it's clear. I only checked the main breather nipple.

I realize that the diff running hot is extremely bad, but if thats the problem, would it really cause leaking like this?

I would post pictures but to top this weekend off, I dropped my phone into water and dont have another means of taking pictures besides my laptop. It's been a pricey weekend...

 

[BrandonF]

It is normal for pressure build up hence the reason for the breather. Did you replace the gaskets and or seals when you replaced it and if not why not? If you got it out, I would replace every seal and gasket that I disturbed. To find the leak, clean it up real good with some brake clean. That stuff leaves a dry finish. Take the truck for a quick, brisk drive. May only need to take it down the street. Don't go far. If you have to, pull over and crawl underneath to see where it's coming from before the oil gets everywhere and you won't be able to see where it's coming from. Good Luck!

This was a full axle swap, so none of the seals were touched. When I get home from work, I will try your suggestion. Before the leak went crazy, it was clear that it was coming from the top of the elocker actuator area. At first I thought it was just the breather, but I've ruled that now by extending the breather and not having any fluid coming out the top of the hose.

 

[BrandonF]

Stupid question, but did you use new gaskets? Even if you didn't nick one on the clean up, they may be bad even if they look good. It's always a good idea to replace gaskets anytime you take something apart that relys on them for a seal. Just a thought. Hope you get it sealed up.

As I mentioned to JRZEE2000TR4LTD, this was a full axle swap, so I did not dismantle anything that involved a gasket. But yes I totally agree, anything thats taken apart with a gasket should get a brand new gasket for sure.

 

[TheeMikeB]

Well if it was a full axle swap, the problem was most likely there before you. Have you checked the torque on the diff nuts? Should be 18lbs on all of them.

Is the axle you swapped in a factory installed elocker? Meaning... was the axle you got 'retrofitted' to fit an elocker or was the elocker factory installed? If it was retrofitted, that is a tricky process and could have been done incorrectly and it could be leaking around the cuts.

OR... it is possible you just have a bad gasket in there and you may need to pull the diff, clean it up and put in a new one. Or use FIPG.

OR it could be coming from the Pinion Flange... leaks are tough to trace because driving at speed with wind can blow the oil all over the place... pics would help too.

 

[Kurtis]

x2 on checking the differential bolts/nuts but I'd be more interested in looking at the pinion as that would throw gear oil everywhere.

 

[BrandonF]

Well if it was a full axle swap, the problem was most likely there before you. Have you checked the torque on the diff nuts? Should be 18lbs on all of them.

Is the axle you swapped in a factory installed elocker? Meaning... was the axle you got 'retrofitted' to fit an elocker or was the elocker factory installed? If it was retrofitted, that is a tricky process and could have been done incorrectly and it could be leaking around the cuts.

OR... it is possible you just have a bad gasket in there and you may need to pull the diff, clean it up and put in a new one. Or use FIPG.

OR it could be coming from the Pinion Flange... leaks are tough to trace because driving at speed with wind can blow the oil all over the place... pics would help too.

It is a factory installed locker. The weird thing is that it doesnt appear to be coming from the junction between the 3rd and axle housing, nor does it appear to be coming from the pinion flange. When I first noticed the leak, only the elocker actuator area was wet. Everything else was bone dry.

I will try to get some pictures, but as mentioned, I lost my phone to water damage yesterday.

 

[BrianSD_42]

Do you have access to a Go-Pro ?

Add oil back into the housing. Mount the Go-Pro so you can see the elocker and drive around town. Use the video to see where the oil is coming from.

When I was referring to the seals and bearings I was talking about the axel seals which leak onto the brake drums.

Is there axle oil on your brake drums?


:brick:

 

[riflecountry]

There is a small O-ring around the E-locker motor shaft. The way you describe it, it could be leaking there.

 

[BrandonF]

This is what Im suspecting. It should be leaking out of the bottom of the elocker actuator, not the top though. Im about to pull it apart and see whats going on.

 

[BrandonF]

There is a small O-ring around the E-locker motor shaft. The way you describe it, it could be leaking there.

I cleaned the whole axle off with brake cleaner, took it for a quick spin (literally about 30 seconds of driving was all I needed to get the leak going) and managed to get some pictures:

In the two pictures, the three red arrows are where the leak appears to be coming from.

Now, the blue arrow is pointing to a hole that does not have any threads. What is this hole for? As far as I know, it's supposed to have a stud coming through it that is threaded into the axle housing and then a nut on the end, much like the threaded stud in the bottom right hand corner of the 3rd member/axle housing? Please tell me I am wrong.

So, my attention is again turned to the o-ring that sits around the splined shaft that is turned by the elocker motor. This seems like the only way that oil could be leaking from where it is.

How do I remove the elocker actuator module to inspect this o-ring? I removed the two bolts on the bottom of the actuator but it seems like it may take some tapping from a hammer to break it free. I've read that it can be quite tight.

 

[BrandonF]

I popped off the elocker actuator unit and everything makes sense now. The top stud is missing and as you can see in the picture, the whole top part of the actuator is not sitting up flush against the 3rd member, therefore not allowing the o-ring around the elocker actuator shaft to seal. This also explains why the leak has appeared to come from the top of the actuator, not always the bottom.

I do have one question: I've heard that you must remove the 3rd member to install said stud. I don't see why. Can I not just insert it in the hole and thread it in? I stud a long narrow screw into the hole and I can feel the threads in the axle housing. The threads feel intact and the hole goes back quite far. I was worried that the stud could be snapped and still in there but as far as I can tell, it's simply missing.

Another question: Why the **** is this stud missing in the first place??!!!

 

[Swede]

Bump?