Rubicon Front Diff Shavings - What is Normal?

[gato]

2021 JLUR with the full-time AWD D44 axle (axle is all stock, except for G2 Diff Cover).

Jeep has 20K mikes total, 18K since last diff fluid change (when G2 cover installed). About a dozen off-road outings (mostly green/blues, some blacks) and a few dozen front locker engagements. All feel normal.

Changed diff oil today and was amazed at the shavings on the front diff plug (pics) below. No bigger chunks found and oil looked clear and nearly new. Rear garage just the paste and fluid was a bit darker as expected.

Question:

Are these shavings normal for jus 18K miles on front diff between changes?

Thank you. It’s only my second time changing diff fluid, so I don’t know what is excessive or expected.

Sponsored

 

[BUSHRVN]

Those look like machining shaving from the manufacturing process more than anything, like it wasn't cleaned out properly.

 

[kah.mun.rah]

Unfortunately I would say that is enough to make me want to pull the cover for internal investigation.

 

[gato]

Those look like machining shaving from the manufacturing process more than anything, like it wasn't cleaned out properly.

I waited until ~1,500 miles, including some good amount of miles in 4HI (straight line) and locker use off-road, before putting the aftermarket cover on.

At that time there was just minimum metal paste and some small particles (1mm size) in the drain plug. I thoroughly cleaned and inspected the diff - everything looked pristine (no scoring, missing chunks, rough surfaces, etc).

Then 18K miles later I find this.

Honestly, I only changed the diff fluid to see if removing suspended metal from the fluid decreases my chance of getting the locker sensor failure - otherwise, too soon to change it. (or so I thought)

 

[gato]

Unfortunately I would say that is enough to make me want to pull the cover for internal investigation.

Anything specifically I should look for? (just eyeball the gears?)

I'm far from versed in what a 20K mile diff should look like.

 

[6.2Blazer]

If I found that in any axle I would be concerned! Honestly have never done a front Rubicon JL axles but have changed fluid and completely rebuilt several axles in my life and anything like shown in those pictures would concern me.

 

[John VonJeep]

Pull and inspect. You’re not going to feel ok until you do.

 

[gato]

Pull and inspect. You’re not going to feel ok until you do.

Yes. I'm going to drive for ˜2K miles and pull the cover. This way I can see if it is continuing or was just break-in shavings.

Thing is, other then eyeballing the gears I wouldn't know what to look for

 

[toothirtyj]

Thing is, other then eyeballing the gears I wouldn't know what to look for

Also look for more shavings and chunks of metal.

 

[GrayWolf.Overland]

4hi straight line on tarmac with full-traction turns?

even in that case i blv the axle shaft takes the brunt and not the R&P gears ?

 

[gato]

4hi straight line on tarmac with full-traction turns?

even in that case i blv the axle shaft takes the brunt and not the R&P gears ?

No turns. I just run occasionally on a straight line to get the diff spinning, oil on the gears, etc + did it at break in prior to changing diff cover.

With the full time transfer case it is trivial to momentarily move from 4Hi Auto to 4HI Full Time.

 

[GrayWolf.Overland]

No turns. I just run occasionally on a straight line to get the diff spinning, oil on the gears, etc + did it at break in prior to changing diff cover.

With the full time transfer case it is trivial to momentarily move from 4Hi Auto to 4HI Full Time.

Ah full-time 4wd with CV boots.. ignore my comment :D

 

[Old Dogger]

That needs to be inspected. Not normal!

 

[6.2Blazer]

Yes. I'm going to drive for ˜2K miles and pull the cover. This way I can see if it is continuing or was just break-in shavings.

Thing is, other then eyeballing the gears I wouldn't know what to look for

In any case what is shown in the picture is not normal, break-in or not. The best case scenario is that the axle or other internal parts were machined in the factory and they simply didn't clean out the metal filings before installing....basically the chunks were just floating around in side the fluid. That's not good, but also doesn't mean everything is going to explode either. If those chunks were actually worn off or broken off from rotating parts in the diff it's bad.

 

[Tangokilo]

Not normal.

Sponsored