Rear diff leak

[ausie]

I noticed a few oil spots where the car sits.... first thought nothing to wory about until I inspected what it was.... gear oil :( . Lifted up the car to inspect the diff housing for cracks and what I could see did not seem to be much of an issue, just the seal looked like it was torn at the bottom where the fluid was comming out. The spot on the garage floor came about shortly after getting my car back from service when I had the clutch, flywheel, pressureplate, TOB, and guide tube replaced. Seems a bit coincidental to me. I did check to see if it was coming out of the vent tube (that can happen if the diff overheats). I am sure I could fix it but fear that the entire rear end needs to be dropped just to remove the differential cover. The cat back needs to come off. IF I am going to go to all that trouble, may as well change the clutch pack if it has one in the differential. Any suggestions?

[WVSNS&]

Almost the same thing on my 01. After the clutch was done, the rear was wet. I had it resealed but now due to the extenuating circumstances...the low speed turning rear end noise I have had since 22k, I am getting the new carbon fiber kit for the rear from ford. All is on order or more to the point shipped. I am anxiously awaiting these parts and the new gears. Hope there will be no more driveline sloppyness. Quite a few people recommended these new fiber deals for the rear, I think it is the best way to go.

[ausie]

It does not look like I would be able to remove the diff cover without dropping the drive shaft. Not quite enough room to clear the gears if I loosened all the bolts. Since I was in there I did a full inspection on the housing and did not find any stress cracks. Had to drop both sides of the exhaust. Also pulled the fill plug to see if there was any fluid in it. Could not feel a thing. Went to the nearest auto parts store and got some permatex "right stuff", a syphen pump and some gear oil. Leak seemed to be just in one area at the cover seal (at least it was not sourcing from one of the axle seals). That permatex gasket material seemed to work great (placed a 1 inch wide bead spread out over the two mating surfaces). It nearly took one full quart of gear oil before it started to overflow the fill plug hole. I also added some CD2 oil stop leak to the gear oil in hopes that it would aid in preventing any further leaks. Overnight not a single drip from the differential. Will have to drive it today and see if it holds up. Considering the assumed amount of fluids in the differential, it sure was quiet. I think this also was the sourse of the clutch burn smell since it was dripping onto the exhaust pipes.

[ausie]

So far it has not leaked yet since I put the bandaide on it. Having second thoughts on removing the diff cover but think it can be removed if the rear support is held in place by the single bolt attached to the rubber bushing. If this is the case, does anyone know if there is a stronger differential cover on the market. I will also be looking into the diff cover girdle that Billetflow offers. I have seen others but would think the steel one is stronger than the aluminum one's. I still would consider removal of the cover to clean out all the gunk and metal shavings (if any). I am sure I can figure it out sooner or later but if someone has done it before any hints would be helpful. Thanks. :thumbsup:

[RR03Cobra]

My last snake had the same problem. Is your ride out of warranty?? The reason I ask is that Ford has a service report on this problem. I took my last car in and they fixed it. Actually replaced the whole center piece. After reading your post, I checked the rear on my current snake and found it to have a small leaking problem also!! Unfortunately, my car has 40,000 miles on it, so it's out of warranty!! Did you just clean the area of the leak and apply the Permatex? I might have to do the same thing as a band-aid too. I think the rear cover is a piece of crap!! They actually attached some of the IRS to the center aluminum housing!! This was a bad design! My pal blew his cover into pieces at the last SCMC track day at Jackson!! I guess I will also check my fluid level today!!
When we got my pals car back to the shop, we had to disconnect the drive shaft in order to access the cover! It is a PITA. Good luck!

[ausie]

My last snake had the same problem. Is your ride out of warranty?? The reason I ask is that Ford has a service report on this problem. I took my last car in and they fixed it. Actually replaced the whole center piece. After reading your post, I checked the rear on my current snake and found it to have a small leaking problem also!! Unfortunately, my car has 40,000 miles on it, so it's out of warranty!! Did you just clean the area of the leak and apply the Permatex? I might have to do the same thing as a band-aid too. I think the rear cover is a piece of crap!! They actually attached some of the IRS to the center aluminum housing!! This was a bad design! My pal blew his cover into pieces at the last SCMC track day at Jackson!! I guess I will also check my fluid level today!!
When we got my pals car back to the shop, we had to disconnect the drive shaft in order to access the cover! It is a PITA. Good luck!
I could have taken it into the Ford dealer, but after a very close inspection there only seemed to be a small leak where the gasket material was very thin. One reason why I did not was I have read in other web sits that the leaking differential seals when fixed by dealer turned out worse that it was before the cars were taken in.

Before I used the permatex sealer I cleaned the entire area where I planned to use it with brake parts cleaner. You want to make sure that the area is clean and free of road debris and any fluids. Even though it was still leaking when I applied the gasket material it just stuck to it. I covered the entire surface along the bottom side overlapping the cover and housing. I will post a picture of the gasket seal as soon as I have time to do so. Best to locate the area where the leak is first. Also you need to drop the exhaust to get more access area to work in as well as to remove the fill plug. If anybody knows where the drain plug is (if it has one that is.....). The place where the gasket was leaking used to have more gasket material there. Almost looks like someone pulled the gasket seal that was sticking out which may have caused the leak in the first place since I found it just hanging loose in that spot.

Also when I launch at the track I am not dropping the clutch at high RPM. I have not yet launched at more than 2500RPM. I basically know just about every inch of my car. The leak did not show up until after getting new wheels and tires. Since the tires hook like mad it may have resulting in more strain on the cover. Since I have put the bandade on the differential it has not leaked yet. Make sure if you get the gasket seal it comes in the can. Permatex item # 25223. I definately give this product a :thumbsup: