Front Diff cover and Diff damage

[sjed21]

Hi All, first post on the forum here. I have some damage to my front diff cover and into the diff housing a little bit. It’s causing a very slow leak, no dripping at all. Local 4x4 shop said they would fix by welding new metal on then grinding flat. My other option would be getting a new diff cover and seeing if the rtv gasket would hold. The damage doesn’t look super deep on the housing side. Any advice?

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[Bandit’s Lair]

New diff cover, RTV it thick, diff armor. Unless you’ve got the xtra cash to get a weld up job done on it and you trust that shop. Theres a lot going on inside there and I personally wouldn’t feel good about the welding process.

Did you slip off something and land on it or wedge it on a rock?

 

[sjed21]

New diff cover, RTV it thick, diff armor. Unless you’ve got the xtra cash to get a weld up job done on it and you trust that shop. Theres a lot going on inside there and I personally wouldn’t feel good about the welding process.

Did you slip off something and land on it or wedge it on a rock?

Honestly have no clue how it happened, can’t recall even hearing a sound on trails that would make me think I hit something

 

[bd100]

Armor to consider for the future:

Diff guards for the stock cover:
https://purplecranium.com/ag-432.903656-jeep-gladiator.html
https://www.rockhard4x4.com/product_p/rh-9084.htm

or any number of cast or plate replacement front diff covers.

 

[whiteglad]

I'd get a Cav Fab or Motobilt steel cover and install with Ultra black or ultra gray RTV.

 

[Svenable]

I would recommend you pull the cover and see if the entire mating surface around the damaged area is impacted. Use a straight edge to see if the diff housing is flat on the mating surface closer to the inside of the seating surface. If it is then get a new cover, I recommend on of the cast ones, and install the cover.

People usually peel the covers back breaking the seal , I've never seen the housing bend like that, which doesn't really mean anything. There are lots of things I have not seen.

 

[bd100]

Whatever bent back the diff housing like that may have done real damage to any aftermarket diff cover as well. That's quite a hit, there.

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