Teraflex diff cover issues

[bumpit]

Regeared the jeep over the last weekend and had a teraflex diff cover to put on. I've used their old style covers on my jk but after 6 attempts I gave up trying to get it to seal and just put the factory cover back on. It was constantly leaking from the bottom.

I tried two different types of rtv, putting the rtv on the cover and the housing, I let it sit over night to make sure it had set properly and I even used guide pins to make sure I was getting proper contact.

The holes on the bottom have an incredibly thin piece of metal to put a bead of silicon on and I'm thinking this is why it's constantly leaking out of that hole.

The green circle with the x is the hole in question. Any ideas to make it fit? I want it to work but after 6 attempts with the same leak spot I'm thinking it's not me.

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[jaymz]

If you aren’t using “The Right Stuff” (black) by Permatex, you aren’t using the right stuff. I’ve been using it for probably two decades and have had zero failures. Brake clean everything, and if need be, jack the vehicle up to keep residual oil from running onto the sealing surface and you’ll be good to go so long as the cover doesn’t have any major defects.

 

[zrickety]

Regeared the jeep over the last weekend and had a teraflex diff cover to put on. I've used their old style covers on my jk but after 6 attempts I gave up trying to get it to seal and just put the factory cover back on. It was constantly leaking from the bottom.

I tried two different types of rtv, putting the rtv on the cover and the housing, I let it sit over night to make sure it had set properly and I even used guide pins to make sure I was getting proper contact.

The holes on the bottom have an incredibly thin piece of metal to put a bead of silicon on and I'm thinking this is why it's constantly leaking out of that hole.

The green circle with the x is the hole in question. Any ideas to make it fit? I want it to work but after 6 attempts with the same leak spot I'm thinking it's not me.

I agree that looks incredibly narrow for a good seal, and it doesn't look very flat from this pic. If you can return for a refund, that's what I would do. Find another aftermarket cover.

 

[Ratbert]

@TeraFlex might have some insight.

 

[bumpit]

If you aren’t using “The Right Stuff” (black) by Permatex, you aren’t using the right stuff. I’ve been using it for probably two decades and have had zero failures. Brake clean everything, and if need be, jack the vehicle up to keep residual oil from running onto the sealing surface and you’ll be good to go so long as the cover doesn’t have any major defects.

The install was after a gear install the axle was free of any oil etc and it was on a lift. Permatex black and the stuff that came with my Yukon gears were the two I tried.

The cover and the housing are both flat and the stock cover has sealed right up first try after 6 fails with the teraflex cover.

I like the cover and I'd love to be able to make it work.

 

[TeraFlex]

Sorry to hear you're having issues! By chance, do you know if it's leaking around the bolt holes, or through the bolt holes? Hopefully I'll be able to help you get it sorted and figured out.

 

[RAO]

Was this issue with the @TeraFlex cover resolved? I just purchased the front and rear covers and notice the same narrow space for the gasket material. I won’t be installing them for about two months and dont want to run into this same issue then.

 

[falcon241073]

Are y’all not trying to reuse the stock gasket? I reused it with my metalcloak cover and no issues. I used lubelocker with my teraflex covers on my jk no problems.

 

[bumpit]

Was this issue with the @TeraFlex cover resolved? I just purchased the front and rear covers and notice the same narrow space for the gasket material. I won’t be installing them for about two months and dont want to run into this same issue then.

Yup they sent me a new cover in a couple days and it's done it's job. Drug it over a lot of rocks in Wyoming and drove home 17 hours no leaks.

When you manuf a lot of stuff your bound to have issues here and there and if the company takes care of it that's a company I will happily buy from again.

 

[bumpit]

Are y’all not trying to reuse the stock gasket? I reused it with my metalcloak cover and no issues. I used lubelocker with my teraflex covers on my jk no problems.

I honestly don't see a reason it wouldn't as it's a really nice one actually. I vaguely remember the teraflex instructions saying it wasn't compatible so I just used rtv but I don't have them in front of me. I reused it between a couple fluid changes with the factory cover.

 

[RAO]

Yup they sent me a new cover in a couple days and it's done it's job. Drug it over a lot of rocks in Wyoming and drove home 17 hours no leaks.

When you manuf a lot of stuff your bound to have issues here and there and if the company takes care of it that's a company I will happily buy from again.

Thank you for responding. I will reach out to @TeraFlex about getting a replacement cover. Will post my experience when done.

 

[bumpit]

They also did a lousy job facing off the flange. I clearly see machining marks. That’s not good.
I always use gaskets. My technique:
1. Initially, thoroughly clean both surfaces.
2. Mask and spray Permatex high tack spray-a-gasket sealant to cover flange and let it set up a few minutes.
3. Apply light film of grease to diff housing gasket surface.
4. Attached cover and torque bolts.
I’m able to get a few diff oil changes with the same gasket. NEVER had any leaking.
Cover comes off without any scraping needed.
When it’s time to replace gasket, brake cleaner or gasoline easily breaks down the Permatex. Wipe clean. Repeat.
Just Say NO to RTV unless you’re doing a trail repair. My 2 cents.
I’ve rebuilt transfer cases and have found excess RTV sealant clogging the oil pump pickup screens.

Those marks you see are from me wire wheeling the paint coating they put on it off. It didn't come like that ?

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