Rear Diff Leak

I am trying to solve my rear diff (D44) leak. I assumed it was because I had scuffed the differential housing removing the old RTV, so I bought a lube locker seal, and it probably helped a little bit, but not enough. I was going to try applying a thin layer of RTV on the housing before I put the cover and gasket back on, but I am wondering if using a stiffer aftermarket cover might solve the problem. Has this worked for anyone on the site?

Thanks.

 

I used a front 44 cover like a stock Rubicon. It was relatively cheap.

But yes if you overtighten the bolts it can pull the holes in the stock cover. Also remember that some of the holes go through to oil so you need to have something to seal the bolt threads.

 

Skip the seal entirely and use permatex "the right stuff"

 

Yes. Permatex #2, or their Aviation Sealer. I totally quit using RTV a long time ago.


Also... diff covers often get the bolt holes distorted by overtightening. Then they won't seal. Lay it on an anvil and use careful hammer work to reverse any dimpling at the holes and make the sealing surface "flat or better."

 

IMO, the stock covers are something close to tin foil. Get a replacement. There are a number of factory D44 covers that are made of 3/16" material. Those do not distort with fasteners, are much less susceptible to dents, and don't peel on the bottom when abraded. Time for a visit to the pick and pull.

 

I had to recently do this to my valve cover for the same reason. Didn't have an anvil but the edge of a 2x4 worked well enough.

 

Is your vent working?

 

This.

And this.
And lay the cover on a flat surface to check for any bent flanges or distortion. Do a tight inspection of the flange edges for any hairline cracks.

Gayle Banks did three ridiculously long videos on aftermarket diff covers and after gutting my way through them concurred that the stock design lubes the front pinion bearings better than non contoured aftermarket "upgraded" covers.

 

If it still leaks with the lube locker gasket the cover flange definitely has a slight warp. Likely from a bolt hole or where someone has tried to pry the cover off. Take the cover off and put a strait edge on the flage of the cover and diff housing and hopefully the cover is the problem. Then uou can hammer and dolly the cover flat again or get a HD cover

 

I went with a G2 cover, solved my leak issues.

 

I don't use a seal but I'm very meticulous when doing the diff.

scrape clean paint, acetone on surfaces, small bead atv(around bolt holes also), Let set for 10 minutes. bolt cover on very loose (barely touching atv), let it firm up, reinstall all bolt with atv towards the bolt head of thread, hand tight then a quarter extra turn, let it completely dry, fill.

Run it until the fluid is warm before changing.

I use a little permatex thread sealant on fill and drain plugs because I don't crank on them. White stuff in small tube. Clean the thread with acetone beforehand.

 

Vent is definitely open. I haven’t driven it since I took it apart. This is just leak from sitting there.