Strange leak on rear differential.

[bjl95mustang]

While I was upgrading my 5100 to 5160 I noticed differential fluid all over the right side.

I cleaned everything off and didn’t see it in the common areas. Tubes, axle seal etc. then I noticed this weird spot on the cover. It’s kind of loose and and it gets wet after solvent cleaning.

Checked my fluid level and I added 16oz.

Anyone see anything like this before???

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[JCsTruck]

If oil is being slung on the rear wheel well liners then could be the axle seals and if you have the max tow package then you might want to check your axle seals to see if the recall for the new axles applies to your truck. Apparently a bolt that holds the axle shaft in place can snap and there are many threads on this forum regarding that topic.

 

[bjl95mustang]

No max tow and not any big sign of fluid by the axle seals. The inside of the wheel is dry.

 

[JCsTruck]

Might want to take that to the dealer then as obviously its leaking. The attached picture is what made me think the axle seals were leaking onto the wheel and then the wheel flinging it onto the wheel well liner.

 

[bjl95mustang]

When I got the truck I coated the whole axle in fluid film because it was rusty as usual. So that’s adding to chasing the issues and trying to clean it all off. But the inside of the rim is dry, as well as the outside of the rim and tire.

The only thing that is remotely wet is that odd point in the diff cover. I have no idea why that cover looks like that.

 

[JohnTrigger]

Is the weird spot seem to be the same hardness as the cover? Is it preventing that bolt that looks to be touching it from tightening down squarely? It looks like there was some sort of defect that was repaired (spot welded) but that’s BS on a new truck. I’d take it back for warranty replacement work, and you’ll get a free differential gear oil replacement as a bonus, getting out the break-in debris “yuck” .

 

[bjl95mustang]

It’s almost like there was debris on the stamp when the cover was punched out. But for the life of me I can’t figure out yet how the fluid traveled down the right side of the axle and slung into the rear wheel wheel, and not getting on the tire…

 

[WBL_Chzhd]

My 2022 PB had to have the rear differential seal replaced twice. I think that's fairly common.

 

[bjl95mustang]

So that spot in the cover that was oozing was popped off and it didn’t go all the way through. I guess it was the cleaner getting behind the cavity and oozing out.

However the fluid in my opinion for 10k miles is pretty dark, no metal shaving just the fine metal particles in the drain plug.

Rinsed everything down with carb cleaner and no visible leaks or even sweating.

Still no explanation as to why it was 16oz low and the fluid coating in the wheel well. Maybe just the right rear tire picked some up from somewhere???

Front differential was full and fluid looked good.

However I did add 1/3-1/2 a bottle of fluid to the transfer case.

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