Chunks in front diff fluid - how bad is it?

[JeepinJoe1234]

I had my 2019 rubicon in for regular maintenance including changing the differential fluids. Last changed at 40k and at 76k now so decided to change it out while it was in the shop. Mechanic found chunks of metal attached to the magnetic screw for the front diff, pulled the differential cover and cleaned out more metal chunks. The shop couldn’t find any issues that would cause this so recommended we just put the cover back on and refill and check again at the next oil change. Any ideas what it could be? How bad is it?

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[dchemphill1]

Those are some serious chunks! Could not find any damage to diff gears? Seems odd. Where did the chunks come from if not the diff?

 

[There’sOnlyOne]

Those look like the spirals you get when you drill into metal or aluminum. Have you had any air lockers installed, diff temp gauge or drilled a vent hole (even though it should already have one).

 

[T Town]

That is swarf. Whether from your destroyed diff or the manufacture of, they must be kidding about not finding any damage.

 

[Old Dogger]

That is serious. The diff needs to be pulled to find out what is failing.

 

[chevymitchell]

I had my 2019 rubicon in for regular maintenance including changing the differential fluids. Last changed at 40k and at 76k now so decided to change it out while it was in the shop. Mechanic found chunks of metal attached to the magnetic screw for the front diff, pulled the differential cover and cleaned out more metal chunks. The shop couldn’t find any issues that would cause this so recommended we just put the cover back on and refill and check again at the next oil change. Any ideas what it could be? How bad is it?

Those are just machining tailings from a poorly washed housing post-production. Nothing to worry about really. The bigger the chunk, the heavier they are, so they likely just hung out in the sump area. I'd just flush it out with some cleaner, service the diff, and press on.

If you're feeling overly concerned, you can pull the diff, but you really won't get access to much more except running a rag down the tubes.

I'd have no issue rolling on with this after a good rinse, cleaning, and service.

Edit: Since it's the front axle, I would add a step to pull the FAD motor and inspect inside since there could be debris behind that intermediate shaft bearing but I doubt it. Easy enough to check though.

 

[azjl#3]

Those are just machining tailings from a poorly washed housing post-production. Nothing to worry about really. The bigger the chunk, the heavier they are, so they likely just hung out in the sump area. I'd just flush it out with some cleaner, service the diff, and press on.

If you're feeling overly concerned, you can pull the diff, but you really won't get access to much more except running a rag down the tubes.

I'd have no issue rolling on with this after a good rinse, cleaning, and service.

Edit: Since it's the front axle, I would add a step to pull the FAD motor and inspect inside since there could be debris behind that intermediate shaft bearing but I doubt it. Easy enough to check though.

agree, fill and drive.

 

[grimmjeeper]

I had my 2019 rubicon in for regular maintenance including changing the differential fluids. Last changed at 40k and at 76k now so decided to change it out while it was in the shop. Mechanic found chunks of metal attached to the magnetic screw for the front diff, pulled the differential cover and cleaned out more metal chunks. The shop couldn’t find any issues that would cause this so recommended we just put the cover back on and refill and check again at the next oil change. Any ideas what it could be? How bad is it?

It's very bad.

Step 1. Find a better mechanic
Step 2. Show them the pictures and/or the pieces.
Step 3. Have them replace everything. It's all suspect. That much metal means the bearings are probably toast and the gears are likely damaged. It's also very likely the guts of the locker are borked.

 

[WillysMeow]

Those are just machining tailings from a poorly washed housing post-production. Nothing to worry about really. The bigger the chunk, the heavier they are, so they likely just hung out in the sump area. I'd just flush it out with some cleaner, service the diff, and press on.

If you're feeling overly concerned, you can pull the diff, but you really won't get access to much more except running a rag down the tubes.

I'd have no issue rolling on with this after a good rinse, cleaning, and service.

Edit: Since it's the front axle, I would add a step to pull the FAD motor and inspect inside since there could be debris behind that intermediate shaft bearing but I doubt it. Easy enough to check though.

Precisely. But with that much tiny glitter on the magnet I'd tighten up your diff fluid change interval, how many miles since last change.

 

[Nate88cool]

Those are just machining tailings from a poorly washed housing post-production. Nothing to worry about really. The bigger the chunk, the heavier they are, so they likely just hung out in the sump area. I'd just flush it out with some cleaner, service the diff, and press on.

If you're feeling overly concerned, you can pull the diff, but you really won't get access to much more except running a rag down the tubes.

I'd have no issue rolling on with this after a good rinse, cleaning, and service.

Edit: Since it's the front axle, I would add a step to pull the FAD motor and inspect inside since there could be debris behind that intermediate shaft bearing but I doubt it. Easy enough to check though.

As stated these metal shavings are NOT from any failed parts of the differential. These are machining shavings which look like drill shavings. Good chance they have stayed on the magnet the entire time and away from any gears/bearings. Production quality as we know is terrible and not getting any better and this is the result. If all the gears look good and the diff spins freely without any bearing noises or anything I would flush thoroughly and fill. Wouldn't hurt to pull the diff and inspect the bearings but I'd say they are fine. If they were you would of noticed it before this service.

 

[JeepinJoe1234]

Thank you all for your replies! Makes me feel much better about this since it’s likely nothing to be concerned about (assuming all was cleaned out)

 

[Kracka]

Precisely. But with that much tiny glitter on the magnet I'd tighten up your diff fluid change interval, how many miles since last change.

36k miles per OP. Agreed that tighter intervals will be beneficial.

 

[Scott97]

Spirals says it all. This is not chunks as we would see from destroyed gear teeth. Flush, put in new fluid and move on.

 

[Upnarms]

Cracks me up. Half the folks "this is bad! Get a new mechanic! You need a new differential!" the other half "is nothing, just left over shavings, change fluid all is good."

Both absolutely certain they are right. Well this is the difference in $1000s and $50.

I get a kick out of it. Like 2 docs- "I'm sorry, you have 6 months to live." Other doc "you just have a headache, take a couple aspirin"

 

[azjl#3]

Cracks me up. Half the folks "this is bad! Get a new mechanic! You need a new differential!" the other half "is nothing, just left over shavings, change fluid all is good."

Both absolutely certain they are right. Well this is the difference in $1000s and $50.

I get a kick out of it. Like 2 docs- "I'm sorry, you have 6 months to live." Other doc "you just have a headache, take a couple aspirin"

my theory, it drives now, a dealer wont replace anything if they see it, so drive it till it does blow up, and one of 5 did on mine.

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