Front Diff Gasket Leak

My '13 DCSB TRD is at 30k, so I decided to change the rear/front diff and transfer case fluids. The rear and t case went fine. Then I pulled off the skid plate to get to the front diff and found this.

The truck never left oil spots that I noticed and everything has been working fine. This appears to be a slow leak from the gasket between the two halves of the front diff. I'm guessing that the orange rubber strip is a piece of gasket that pressed out during manufacture, or was excess that didn't get trimmed off. Either way it looks to be leaking from there. I don't see any cracks.

I only pulled the fill plug and added oil until it started to overflow. It took 4oz.. I think I read that it's a 1.6qt fill, so being 0.25qt low wasn't as bad as I expected.

It was purchased certified used from a dealer at 15k. The skid was on pretty tight and I'm thinking this is the first time its been taken off.

It'll be sitting all week and I'll be watching for drips. It's still under warranty so I'll take it in next week, a 2hr drive to the same dealership, as long as it doesn't start gushing oil. Anything else I should be concerned about with this? Anyone seen it before? Anyone had a front diff replaced by a dealer?

 

Looks like someone is going to the dealer.

 

That may not be a factory job... It looks like somebody has been in there. I could be wrong, but I have never seen gasket material done that crappy on any factory fresh engine or differential.

I smell fish. Oh it is a good thing you have a warranty. Let us know what they say.

 

Good call. You aren't wrong. That is def not a factory seal.

 

The dealership took one look and said a warranty repair is not a problem at all. I've got an appointment to take it back next week for a 1.5 day repair, to open it up and re-seal it. No discussion over whether it's an original factory seal or not. Warranty will cover a rental car too. I've got the extended Certified Used coverage for the powertrain to 100k, so I'm feeling pretty safe about it.

Been very happy with Prescott AZ Tim's Toyota service dept.

 

Jimmyh, I was thinking the same thing and the Monday/Friday problem assemblies popped into my head. I wonder if some relief worker was putting the FIPG on and saw there was a gap or flaw in the casting or something and put a bunch extra on for good measure and let it go. But how come it was not caught on QC inspection?

 

Glad they will do it under warranty, save big money lol....

 

I experienced a similar issue but the dealer wouldn't warranty mine you lucky duck so I bought a gasket from Toyota Parts Center. The bead job on the sealer looks the similar though, haha, you just either put too much or not enough in my case.

 

I'm within a few months of 60 years old and have been working on cars since I was old enough to hold a wrench. That isn't a factory seal, IMO.

 

Picked up the truck today after this repair. The dealer had it in the shop for two days. It was fully covered by the original factory warranty (I'm at about 31k). The warranty didn't cover a rental during the repair, since apparently that is only covered while waiting for parts. Since it was a pre-arranged appointment, no loaner was given- didn't bother pushing it since I didn't really need it.

According to the service advisor- this is a very rare occurrence; the orange gasket material (similar to FIPG, but I forget the acronym) is a factory seal; and the FIPG (part

$34 00295-01281 Formed-in-Place Transmission Gasket - 3.5 oz. Tube

00295-01281) that they used for the repair is the same, but black in color. Axle seals are part #'s

$10 90311-47027 Toyota Oil Seal - 90311-47027

90311-47027 and 026.

From the service sheet:

"Inspected and confirmed customer concern that the front carrier was leaking where the two parts of the carrier casement meet. Disassembled front suspension and removed front C/V axles and then removed front diff assembly. After removal, disassembled front diff and split casement and resealed unit. [I was told they let it sit overnight before re-sealing to allow the FIPG to cure/seat/whatever] Reassembled unit, resealed any needed areas and reinstalled new left and right front axle seals. After recheck, diff was reinstalled into truck and refilled with OEM gear oil. Road tested and ensured 4WD operation and no leaks in system."

After picking it up, I took off on a 2hr drive with no issues. Overall, an easy experience. Tim's in Prescott AZ has been a great dealership for me.

 

Rule # 1: Never trust a service manager.

 

I've been to enough shady dealerships to agree with that. Just figured it wasn't in my best interest to prolong the discussion and talk my way out of a warranty repair, if it was actually an aftermarket issue. Oh well.