Contact us. Close Menu. JavaScript is disabled. For a better experience, please enable JavaScript in your browser before proceeding. You are using an out of date browser. It may not display this or other websites correctly. You should upgrade or use an alternative browser. Can you overfill a differential? Almost exactly miles ago I did a thorough front end rebuild including the axle seal , complete with a whole lot of Red Line grease in the knuckles.
Recently, my front differential started making some crazy noises clunking and about 10 miles from home it finally blew catastrophically a loud ka-chunk with every rotation.
I've finally got the time to tear into it, and of course step one is to pull the axles. I expected to see my nice Red Line grease still doing great in there, but this is what I saw:. Timpanogos Slim. I think that's what is commonly referred to as "birf soup" The usual cause is a failed inner axle seal. Yes, you just replaced the seal. This happens a lot. Usually, birf soup this early on means that the seal was damaged during installation of the axle. So I can only blame myself Would it have contributed to my differential failure?
Maybe if the diff oil all leaked into the knuckles? Joined Dec 25, Messages Location Iowa. ZRotheohv said:. Click to expand I'd also pull the hose off the breather on top of differential to rule it out for now.
Obviously don't do any water crossing with the diff open to atmosphere, but there is a slim chance it was pressurized. If the Differential is pressurized it has no where to go but out the axle seals. Now might be a good time to get a piece of fuel line and a inline fuel filter to fit, and extend the breather.
Red Merle. Figure out a way to put the next one in evenly too. I use a huge socket with the extension attached to the inside of the socket rather than the outside and tapped it in with a brass hammer, but I am cheap and have a lot of stuff. Otherwise, you can buy bearing race tools, and even spend more money to get a set that will have a bunch of sizes.
I just use different sized sockets. Just tap, tappy, tap, like Happy Gilmore. Keep an eye on how it is going in and don't get it wedged. Just little taps Ah ha!
I knew it wasn't my fault Except the fact I've never checked the breathers For my original question, though, is it possible to overfill the diff enough that something bad might happen?
If you're breather isn't clogged I doubt you'd build enough pressure to burst the seals with just a few extra pumps. Maybe it you fill the case full and even then I think it'd just go out the breather tube.
It is possible to put too much grease in the knuckles. As it heats up the grease will soften and expand. If you really packed it in there it could have tried to push out through your seal. Far more likely that you damaged the seal installing or the seal didn't seat right on worn shafts.
I agree that the seal was damaged at install, most likely. That being said, don't make a habit of pumping in extra 90W when you fill the diffs or t case. Fill to spill, so to speak, and stop there. Just curious. Box Rocket said:. I find it difficult to overfill a diff by too much since it runs out of the fill hole when it's at the correct level. I used a LubeLocker gasket and a cover that has both a filler and drain hole so I shouldn't have to remove it again when doing the gear oil change.
So now my question I have noticed some wet fluid around the bottom of my '01 XJ and wasn't sure what it was. It was covering the Drivers Lower Control arm, the vacuum tubing and the front driveshaft. At first I thought it was coolant because it's sorta green but there are NO coolant leaks and upon further inspection tonight I believe it's the gear oil coming out the breather tube then running down and getting all over the driveshaft and other running gear Is this what happens when you overfill a differential?
I know I've overfilled my AW4 transmission one time and it started pushing fluid out the dipstick tube. Input is appreciated. Can I damage any bearings or my gears? Should I just drain it out and put in a specific amount of fluid and not do it until the fluid starts to drain back?
Thanks for the input. You should only fill it up to the level of the factory hole. It takes about 1. I am not sure how you can remove the excess short of trying to shove a tube in there and pumping out somehow. It is likely easier to drain and refill. I use the Fel Pro gaskets instead of the fancy Lube Locker. Use the drain plug and let it all drain out, measure the correct amount going back into it, done. Will it do any damage driving it while it's over full I can't fix it until after I drive it to work tomorrow It will expand out the vent tube like it did, and bring down whatever junk is inside the tube when it cools down again Normal routing for the breather tube is along the driver UCA and up the firewall, zip-tied to a hard line next to the brake booster.
The gear oil could foam up and not properly lubricate. I would not drive it any more than I needed to with it so overfilled. Others have done it and I haven't read about their differential failures later, but it can't be good if you know what I mean. May 8th, , It is like a stormy sea inside the diff while your driving, a little extra fluid is unlikely to hurt anything if the vent is open. A lot extra and your guess is as good as mine.
If it builds pressure as the oil heats up and expands, bad things happen. Last edited by 8Mud; May 8th, at Thanks for all the input! That's the first time I've driven on the hwy since doing the fluid change. Most of my driving is around town between mph. I overfilled both of mine last time I changed the fluids. The extra "burped" out on my drive from Houston to Big Bend. I thought I was going to have to replace the seals, but its not leaking now and the level is good now.
May 11th, , So far so good The new covers tend to have the fill port higher because they don't know if people will be putting an axle at more of an angle or not at least that's the reasoning I read somewhere. Always try and put in the correct amount or at least close. A little extra won't hurt excess from that will burp out the vent tube A LOT extra may cause some issues the little vent tube can only vent so much at a time.
If you are worried about it, it's not too hard to pop the cover off and refill. The correct oil level is not determined by the fill hole location for most, yes stock they locate it correctly for stock caster, level ground, etc. But once its lifted or on a hill, or aftermarket covers, etc. That goes out the window. The correct level is best thought of as Draw a line level to the earth on level ground is the best way to do this , straight across the cover from bottom of axle tube to bottom of axle tube on opposite side.
This should be at the bottom of the axle tubes. This will never leave you with too much nor to little oil in a diff. All your drivetrain And Jeep needs at a Discount! If it is for a Jeep we can get it for less and with superior service. All items ship FAST! March 2nd, , Ressurrecting this thread for a minute. I just did my d30 front diff fluid and filled it till it was coming out the drain plug hole. Jeep was parked level. Is this correct? Also, when replacing the fill plug, should I put anything on the threads.
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