Front axle leak. Detectives needed!

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Hi all,

I have a High Pinion Dana 44 from a 1976 Ford F-150 under my 2001 TJ. I did the swap recently. It is currently leaking grey oil, and I can not for the life of my figure out where it’s coming from.

I opened up the fill bolt to determine if water is getting into the diff to turn it grey and it is (pictured).

Here are some photos. If anybody could possibly help me determine where the water is leaking into it and oil is getting out I would owe you big time

 

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Here are some pics from the trip yesterday in Elbe

 

[Cooper Smith]

Hi all,

I have a High Pinion Dana 44 from a 1976 Ford F-150 under my 2001 TJ. I did the swap recently. It is currently leaking grey oil, and I can not for the life of my figure out where it’s coming from.

I opened up the fill bolt to determine if water is getting into the diff to turn it grey and it is (pictured).

Here are some photos. If anybody could possibly help me determine where the water is leaking into it and oil is getting out I would owe you big time

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Pinhole in the cover?

 

[macleanflood]

Not sure I can tell where the breather tube is...but that'll be my guess.

-Mac

 

[Processing]

Pinhole in the cover?

Thanks for weighing in. I don’t think it’s the cover, the red leak is just some lock tight that dripped down from tightening my track bar nut. I wanted to get the pictures prior to cleaning it up.

The grey fluid in the back is what I’m trying to find the source leak for.

I appreciate the response though. Any spitballing is helpful at this point, I’m banging my head against the wall right now

 

[Processing]

Not sure I can tell where the breather tube is...but that'll be my guess.

-Mac

The diff breather is on the front picture, I connected the tube after the axle swap but didn’t put a clamp on it. Maybe that’s what’s causing it, but I didn’t see any oil near it.

Another thought is that since it only will leak while it’s running, perhaps the wind speed pushes it to the rear

 

[Mac57]

The diff breather is on the front picture, I connected the tube after the axle swap but didn’t put a clamp on it. Maybe that’s what’s causing it, but I didn’t see any oil near it.

Another thought is that since it only will leak while it’s running, perhaps the wind speed pushes it to the rear

Seems pretty clear from the milky oil escaping from the plug in the cover you have water inside the diff. Diff breather fitting is the most likely source of water entering the diff. Pull the breather hose off and clean all the gunk off the connection and inspect for cracks. Inspect the hose for a tear or hole, make sure it is extended and securely fastened up high enough to be above any water you drive through, and that the hose inside diameter makes a snug fit. And clamp it when reinstalling on the diff.

You need to change the diff oil as well, while you have the cover off check for cracks in the housing and cover itself. Another area to check would be the seals where the driveshaft meets the housing. Not sure if your Dana 44 axle has internal and /or external seals on the axle shafts, those could be a leakage source as well.

 

[LONGJP2]

Hi all,

If anybody could possibly help me determine where the water is leaking into it and oil is getting out

Probably the same spot.
A hot axle creates pressure. If you dunk it in cold water, it can change to a vacuum and suck the water in.

 

[hosejockey61]

Probably your inner axle seals if the vent is good.