Front Diff Venting Fluid...

[marc11]

I noticed some gear oil all around the outside frame member on the left side and in a few other spots today, I can see fluid on the bottom of the diff, but it is not blowing back. Most of it is on the frame and it seems to be mostly concentrated to what appears to be a vent line. It looks like the front diff is pushing fluid up through what appears to be a vent line. Would an over filled situation cause this or something else?

I changed the fluid myself about 5 months ago, I basically filled it until the fluid started to run out of the fill hole, so if over filled it could only have been slight.

Any thoughts or ideas?

 

[ForOffRoadDriving]

are you sure its diff fluid? have you checked your level to confirm that it is indeed leaking from the vent hose and its not another problem like an engine oil leak or some other lubricant?

 

[marc11]

It is diff fluid for sure, the oil pan and everything else is bone dry and I can see/smell that it is diff fluid.

It seems Ford issued a TSB for this in 2005 as a problem with the 2001 to 2005 Ranger, Explorer, etc. Crap. The fix is a new diff cover and vent line with a baffle. No idea if this is still covered as it doesn't seem to be a recall so I doubt it.

Now what, this is a problem because it is making a mess and I guess would eventually vent out too much fluid.

Anyone else have this and know a fix?

 

[ForOffRoadDriving]

i got one of those baffled vent lines from the junk yard and i put it on the rear of my 94. its really nothing more than a plastic hose barb with a breather on the end of it. how low is the fluid in your diff? does it seem like its blowing alot of fluid out or is it maybe just the small amount that was over filled (did you let the fluid run back out of the hole after you saw it start coming out or did you put the plug in right away)?

 

[marc11]

I haven't checked it yet. When it started to run out, I squirted a bit more in there so it was running out pretty good and then closed it up. There is a fair amount of fluid there, but to be honest, it was pretty gunky and wet there when I got the truck, so it has been doing this for a while I guess. The front diff was a little low when I changed the fluid, nothing came out when I opened the fill hole, but I could feel some fluid if I stuck my finger in there. I guess it doesn't take much to make a mess.

So I am wondering, can I just put a vent filter on it then? Like a little K&N job?

 

[ForOffRoadDriving]

you probably could put a k&n breather on there, but if it got oil seepage through the cotton it would turn into a big dirty ball on the end of the hose. i got my baffle off from an 05 or something new like that in the junkyard. it was easy to get because the motors are already pulled and the tubes are just laying on the frame rail. your fluid level should be about an 1/8" below the hole, high enough to feel fluid when you put your finger in the hole. im sure you could go to a dealer and tell them the part you need and be able to get one for around 5 or 6 dollars.

 

[marc11]

I checked with the dealer. The parts to correct this per the TSB come to $600 plus $225 labor, it is a new diff cover with a baffle and a new vent line, along with some new bolts and of course gasket. No freaking way I am paying that. There has to be a cheaper solution, even if it is rigged and looks like crap.

 

[kunar]

you could probably get a hose barb and some hose from the hardware store and run it to a catch can, maybe mounted on the frame rail or core support. a water separator for an air compressor should work, or maybe a catch can intended for a pcv vent line on an engine.

 

[marc11]

Yeah I thought about that too. I just checked the diff fluid and the level is okay, so my guess is that it is misting out now and then, and has been since new and the PO never noticed. When I go through a car wash, like I did last night or when it rains or snows, I am guessing the caked on gunk drips down some.

What I am thinking is adding a foot or so of hose straight up into the engine compartment, putting the cap on the end of that and then wrapping a rag around the cap to see if that fixes the issue.

 

[V8 Level II]

My 2003 FX4 Level II has the same differential housing vent as yours but does not leak. The factory hose from the vent goes up high and is clipped to a bracket by the brakes lines that connect to the ABS pump. Check to see if you have the same setup. If not, it would be easy to make up something similar for your 04.

 

[marc11]

Nope, I do not, but that is what I was thinking of doing, thanks! My vent stops on the frame rail near the bottom part of the front shock. I am going to run it like yours and see what happens.

 

[polkat]

I got the exact same issue and thats what I am going to do is extend the factory hose higher hope that that helps

 

[Evan]

I checked with the dealer. The parts to correct this per the TSB come to $600 plus $225 labor...

I would use a longer breather line with an accumulator/catch can at the top.

 

[kcm1582]

I think i'm having the same problem. Is this the part you are talking about?

 

[polkat]

ya thats what we have i just raised mine this morning: i need to recheck at lunch;