Front diff leak

A few weeks ago I had an issue I posted about me heating up my front diff and it starting to bind. I changed the fluid and used the 4x4 the next day and everything seemed fine. Now a few weeks later today I drove the truck to work in 2wd about 40mi and park it. Go back outside about an hour after I get to work and there is a puddle of diff oil under the truck about the size of a softball. It was leaking through the skid plate so on brake I took off the skid plate to see if it was the axle seals and they seemed ok and dry. It looks like the fluid is coming from on top of the differential maybe? The steering assembly behind the diff is soaked. The teperatures here have been below 0 the past week don't know if that can effect anything but the truck has not left oil anywhere except for today being the first time. Even after the day I heated it up real bad. Any ideas?

 

How much did you fill it?

Did you check the breather to see if it is coming from that?

 

I filled it until it was coming out of the fill hole it was about 1.25 - 1.5 quarts. I really didn't get to look for too long but how long is the breather hose? Does it come up to the engine bay on the drivers side?

I replaced the fluid in the transfercase and the front diff that day. I filled both until they started to leak out of the fill hole. I bought 3 qts. That day and have a little left over maybe alittle more than .25 of a qt

 

That's about how much you want to fill it so I don't expect overfilling to be a problem. The truck was on level ground when you filled? Or at least nose pointed up the slope?

Breather hose is in the engine bay, on the driver side. Look down between the wheel well and the exhaust header. You'll see a couple of breather valves. I suspect it is coming from there or at the diff end of the hoses but unsure since you had the previous issue.

 

I just can't figure out why it started today. I have used the 4wd 2 times since the over heating and have drivin the truck quite a few miles in 2wd since and now just today the oil shows up nothing in the driveway where it has sat all week

And yes I filled on level ground

 

A few spots it could be coming from:
1. diff breathers -> overfilled or something else is going on
2. diff fill hole -> didn't torque down or has come loose. I think it is 29 lbf-ft but have to check
3. output seals -> you checked and are dry.
4. input seal -> check if you haven't, right behind the driveshaft yoke.
5. stub shaft flange (passenger side of the diff) -> would need regasketing

1-4 can be done with it on the truck and fairly easy to check. 5 would most likely require dropping the diff.

If it isn't 1-4, I'd keep an eye on the level and see if things change until you can get time to tear it apart.