I just had my front and rear axles re-geared. Along with the gears also I had poison Spyder diff covers put on. I am currently stationed in Italy so I took it to an off-road shop to do the gears. I noticed that they used 5-6 quarts of oil for both the front and rear axles. After taking it for a 75 mile breakin drive I noticed my diff fluid coming out of my axle tubes. Should I take it back to them, there is still a lot of diff fluid left? Or should I keep driving due to them overfilling the diffs?

 

That is WAY too much gear oil. The PSC covers have a much higher port, but you don't fill to that level. I don't know the exact amount off the top of my head, but 2 QTs in the rear and 1.5 Qts in the front is more in line with what should've been put in them.


Edit for actual oil requirements.

Front Dana 44
2.7 pints (1.35 quarts)

Rear Dana 44
4.75 pints (2.375 quarts)

 

So should I run it as is or replace the axle seals since it is leaking?

 

Just to point out that depending on mods the fill quantity may be different--aftermarket lockers, different differential covers, etc. However, the proper fill level is still the same regardless of where the fill port is located on aftermarket differential covers: Just above the inside wall of the lower part of the axle tube. Any higher and when really hot it will start to vent out of the differential vent tubes and make a big mess. You want to go no higher than the stock differential covers would allow, if they were installed ("Level of oil at bottom of fill hole") ...

 

I would first get the appropriate amount of gear oil in the axle and see if the seal leak persists. It is very easy to get debris or rig a front seal when pulling/installing the front shafts. But honestly, you could have so much oil in the diff that it is getting pushed by the seals when it gets warm. Keep in mind that once oil gets past the seal on the front it taked a VERY long time to completely drain out of the tube and give you the warm fuzzy the seal is okay again.

Excellent point!

 

Thank you for all your responses I will let it keep draining out and see if it stops. If not I will replace axle seals.

 

both the front and rear at leaking?

when its over fill the diff, you should have a bunch of gear fluid all over you axle housing and engine bay, it shoots out of the breather tube.

the back, will leak the same out of the breather tube.

IF your leaking gear fluid from your front seals, most likely they damaged the seal re installing the axle shaft.

if the rear is leaking, they must of damaged the seal removing the axle shaft, which can happen. they should of put a thin layer of rtv around the seal to secure it.

i'd take it back asap! have them check the seals and replace them. you dont want to deal with the front seal later, it will cost you!!!!

it doesnt sound like your leaking out of breather tube.

 

I've never done this or seen this done. This is something typical of a c-clip axle where the seal is pressed in, but on a semi-float JK axle the seal slides in and is squished into the cup when the backing plate that holds the shaft in is tightened. I do however put a small amount of anti-seize on the outer edge of the axle tube so a ridge of rust doesn't form making removal later easier without a puller. (But I think this is more of an issue for us in the rust belt.)

 

this is common practice, "secure" probably wasnt the best choice of word. the RTV is used a an extra sealant for the seal. if you notice when you pull out shafts on a jk from the factory or in general. you'll see a little bit of rtv.

 

Sorry, but I've pulled several and never noticed this. Additionally, I've been where they are assembled and can assure you this isn't done at the factory.