Help, Metal chunks found in axle

[YY1985YY]

I'm concerned because I found two 1/2" metal chunks after changing my rear axle fluid (def not your typical metal shavings). I will be contacting my dealer as I have the V41 recall coming up at the end of the month. Was this my fault, did I do something directly to cause this??

Lastly, does anyone know how serious this is and what I should be prepared to tell my dealer? I saved the pieces and thought maybe someone here could give me some input. It should be covered by warranty correct?

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[wrangster]

Doubt you needed to change fluid but how did these pieces fit thru the drain plug is beyond me.

 

[YY1985YY]

Forgot to mention my car specs/mileage if that helps.
JLU Sport S Manual Tranny
33K miles

 

[YY1985YY]

Doubt you needed to change fluid but how did these pieces fit thru the drain plug is beyond me.

I don't get why you're doubting if I needed a fluid change, (my rear fluid was almost dark black) and how it's "beyond" you that they could fit through the drain plug. The drain plug is 5/8" (I forget), those pieces aren't 1/2" squares.

 

[wrangster]

I don't get why you're doubting if I needed a fluid change, (my rear fluid was almost dark black) and how it's "beyond" you that they could fit through the drain plug. The drain plug is 5/8" (I forget), those pieces aren't 1/2" squares.

Ok you definitely have more miles than I on mine. So the pieces were stuck to the magnet on the plug I guess and they came out easily then. Your dealer will have to drop the plate to make certain what is actually breaking. Sorry never had the plug out myself but good luck at your dealer.

 

[Arterius2]

Forgot to mention my car specs/mileage if that helps.
JLU Sport S Manual Tranny
33K miles

Do you have the anti slip differential (LSD) by any chance?

 

[YY1985YY]

Do you have the anti slip differential (LSD) by any chance?

Nope but it's the Dana 44 open differential if that's relevant

 

[Tumbleweed]

Metal shavings are normal but metal chunks that size are not. id bring it in to the dealer while its still under warranty to see if they can rip the diff cover off and inspect the gears

 

[Arterius2]

Nope but it's the Dana 44 open differential if that's relevant

It's a known problem for the Dana 44s, especially the LSD version. There is like a 40 page thread on this issue, where people are experiencing knocking sound and finding metal chunks in their diff, along with black oil:
https://www.jlwranglerforums.com/forum/threads/knock-in-rear-with-dana-44.16921/
Apparently it's a design flaw in the clutch plate for the LSD, and there should be a new version coming out soon.

In your case, that looks to be pretty severe. For whatever reason, your rear diff gears are shot, and I would definitely take the matter to the dealers.

 

[JeepCares]

I'm concerned because I found two 1/2" metal chunks after changing my rear axle fluid (def not your typical metal shavings). I will be contacting my dealer as I have the V41 recall coming up at the end of the month. Was this my fault, did I do something directly to cause this??

Lastly, does anyone know how serious this is and what I should be prepared to tell my dealer? I saved the pieces and thought maybe someone here could give me some input. It should be covered by warranty correct?

So sorry to see this! I would like to get you connected with a case manager so they can work with you and the dealership to ensure everything is resolved when you go in for your appointment. Please send your VIN in a private message so we can get started.

Kaitlin
Jeep Cares

 

[CarbonSteel]

Doubt you needed to change fluid but how did these pieces fit thru the drain plug is beyond me.

You realize the majority of all axle wear occurs at less than 15,000 miles, right? Despite longer and longer runs each subsequent oil change will show less and less metal per mile.

 

[wrangster]

Sounds to me like this is something that sport and Sahara owners with the D44 lsd's can look forward to. We can send people to the moon and we still cannot build great cars, sad.

 

[wrangster]

You realize the majority of all axle wear occurs at less than 15,000 miles, right? Despite longer and longer runs each subsequent oil change will show less and less metal per mile.

Typically yes! new gears should be given a break in period.

 

[Headbarcode]

Nope but it's the Dana 44 open differential if that's relevant

Confused with this statement. The 44 rear axle is only available on Sport, Sport S, and Sahara models WITH LSD. The black oil is from your clutch plates prematurely wearing, which would make the oil very gritty and would give you the false sense of having an open diff. I just read through your other thread and saw it being suggested to jack up the rear end and spin a tire to verify if you had LSD or not.

 

[YY1985YY]

Confused with this statement. The 44 rear axle is only available on Sport, Sport S, and Sahara models WITH LSD. The black oil is from your clutch plates prematurely wearing, which would make the oil very gritty and would give you the false sense of having an open diff. I just read through your other thread and saw it being suggested to jack up the rear end and spin a tire to verify if you had LSD or not.

The 2018 Sport S's with manual transmission came with the Dana 44 and no LSD, unless you paid for the LSD. It's on my build sheet when I looked up my VIN, but I Don't know about newer models.

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