Front differential noise and leak on driver's side...

DynoPax · **Posted:** Fri May 04, 2012 10:38 am

I noticed a faint whirring sound coming from the front drivetrain a couple of months ago, but did not bother to check it out more closely. Being in winter time, with noisy tires and whirring going and coming randomly, I dismissed it on the account of road noise being transmitted through the lifted suspension...

Since last week, whirring has become almost permanent. I decided to have a closer look and bingo, there's a leak at the half-shaft link point with the differential, on driver side. Could not see it because of the protection plate, as it sort of contained whatever was coming out of the diff. So, ordered a bearing kit from RockAuto and will do some work this weekend. Hopefully, only the diff bearing should be replaced, otherwise, that may prove more co$$$tly than anticipated :banghead:

, especially if diff housing or half-shaft have sustained damage by excessive wear.

I'll update once assessed and repaired...

DynoPax · **Posted:** Mon May 07, 2012 9:25 am

Only managed to refill the diff, was half-way empty. There is excessive play from driver side half-shaft, so bearing looks shot to me. I'll make some time next week-end and go ahead with replacement...

patmaz · **Joined:** Sat Jan 01, 2011 2:52 pm **Posts:** 134

Hey Dynopax,give me some news on this,im having the exact same issue since last february,with not much time on hands,i just hope my front diff isnt shot,same fluid leak as yours,but no freeplay yet,everything is new in the front of mine,both bearings,brakes,everything,and this noise begins at 50mph to 60mph,and get a little worst when i steer to the right,i feel it right under the fuel pedal,and yes i tought about the tires,they are perfect and i rotate them often,so im pretty sure the diff internal left bearing is shot....

I thought about replacing the left outer seal and litlle bushing/bearing on the axleshaft side,wich would cost around 80$ in parts,but i saw this post,and now im getting pretty affraid that it will take a complete diff job,wich means a lot of money here in canada....i never drive it hard,no offroad,and it has only 110000km,so as you might think,yes i am pissed,i take real good care of it,change oils often,maintenance is up to date,i guess this is the jeep fun going on loll...

viewtopic.php?f=5&t=65841&hilit=seal&start=0

DynoPax · **Posted:** Wed May 09, 2012 12:34 pm

Patmaz,

I bought a bearing kit at an auto parts dealer (Auto Expert) for $120 and will pull out the diff during Victoria Day weekend, it being a big job. Since I intended to move my lift from Daystar to OME, I might as well do the suspension too, especially with the front end dismantled (may also change wheel hubs, while at it)...

The symptoms you are describing are same as mines. I thought first of only pulling out the outer bearing and replace it, but to make sure all is well, I decided on full removal and maintenance, hence a "greasy" weekend in perspective :roll:

arengant · **Posted:** Mon May 21, 2012 8:28 pm

I noticed oil on my drivers side at the half shaft when I was working on my TC and now I hear/ feel the occasional whirring noise so I'll be watching this. Cheaper than a wheel bearing job I hope!

DynoPax · **Posted:** Tue May 22, 2012 8:59 am

Did not get the chance to work on the diff, since I wanted to do the wheel bearing hubs first. Problem was I did not have the proper wrench socket to fit the wheel hub nut (1 3/8" or 35mm) and this being a holiday weekend, with the Jeep on 4 blocks, I simply postponed it. Had enough on my plate already with rotors, calipers and brakes + new oil separator, rear diff oil change, install a class III hitch and repair the intake hose to turbo...

There was a rip at the turbo end, don't know how long it was in this state. Good thing I kept my old CAC hoses, it made repair relatively easy by cutting a few short lenghts to fit over the damaged hose, using some caulking to seal properly...

DynoPax · **Posted:** Mon Jun 11, 2012 12:15 pm

Finally got to the heart of the problem: wheel bearing hubs were shot, especially the passenger-side one. I replaced the diff oil seals and inner sleeves while at it, since I had the parts already. No more whirring sounds from the front-end and that makes me feel much better!

arengant · **Posted:** Mon Jun 11, 2012 6:41 pm

how hard were the diff seals? Did you have to drop the diff itself?

Do you by chance have the part numbers for what you used?

DynoPax · **Posted:** Tue Jun 12, 2012 8:14 am

I did not drop the diff, but pulling the seals out proved to be the most challenging task, especially when you do not have a specific tool to do the job. I ended up devising one, a 12" long bolt (yes, I had one!), passing it through a thick steel plate so the bolt head would rest against it, and put a large-enough thick washer at the other end, between 2 nuts, so it would barely go through the seal's rubber ring. Once in place, I could make the washer sit on the inner sides and wack the steel plate silly with a BFH until the darn seal came off!

After that, I also pulled out the inner sleeve, this time using a thinner bolt with a butterfly hook (same used when you need to set fastener on a drywall to hang pictures) at the end. I grabbed the other end with wisegrips and pulled. You have to be careful not to go too far inside, could scratch, though unlikely with butterfly hook steel quality, or get it stuck and then cannot reach it to take it out...

Diff Parts:
5066056AB Bushings (sleeves)
5066066AA Seals

Wheel hubs:
TIMKEN HA599455L
TIMKEN HA599455R

arengant · **Posted:** Wed Jun 13, 2012 1:24 pm

Great, thanks for the info!

So the leak was from the diff seal (driver's side) but the noise was from the passenger wheel bearing correct? Meaning that the leak and the noise were independent, just two different problems at the same time. I am going to check play in my wheel bearings, but I know sure sure there is a leak so I will have to at least replace that

DynoPax · **Posted:** Fri Jun 15, 2012 10:54 am

Correct! And I am mostly happy about the diff only having a leak problem. My previous vehicle (Chevy Tracker) had the seal, bearing, half-shaft and diff end's frame almost completely worn out. Cost was new diff and half-shaft $$$$$ :roll:

arengant · **Posted:** Sun Jun 17, 2012 9:10 pm

Well I pulled my front Drive Shaft and it seems like the noise went away for me. I will drive it a few more days to make sure I don't hear it. The bad part is the the drive shaft CVs are in great shape, full or grease and everything. Not sure what my noise is still, but maybe it's NOT those expensive wheel bearings!

Front differential noise and leak on driver's side...

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