Front Differential Oil Leak?

Your axles require a gear lube that has a GL-5 rating. The exact viscosity is not important, a 70W-80, 75W-90, 85W-120, etc. is fine. Personally I prefer a conventional gear lube inside our axles (gears run cooler with a conventional gear lube) but for an existing axle a synthetic GL-5 is fine too.
Thanks Jerry for that catch
 
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Hey since your local Napa has the Fel Pro gasket you need, they can also probable get you a Diff Cover if they cannot get you a diff cover Nogalitos gear can its on the Southside of SA off Zarzamora call first before you go

If you want to replace the diff cover
 
As someone who was in your boat not too long ago this last summer, 5 diff fluid changes later (all different diffs) all I have to say don't worry about the gasket, just rtv will do fine, or just felpro, don't get lubelocker for this. I also wouldn't worry about torquing the bolts to spec, I've never used anything bigger than a 3/8ths drive, tightened them until snug and gave them a double check going along with the 10 point pattern.

Also don't call the stores to ask for a gasket and don't walk in either. Your experience may vary but the local pepboys and advanced auto parts in my area seemed to be clueless. Just order the part number via their websites and pick it up. Not that it matters because you'll know as soon as you look at the gasket if it's not the right shape. But just to save you the headache.

RDS 55019 felpro for Dana 30
RDS 13089 felpro Dana 35
RDS 6629 felpro for Dana 44
 
Your diff cover is fine.

Take your cover off...
All bolts out except the top one. Loosen the top one half way. (This way you don't get a bath)
Pry delicately on bottom and side of diff cover. Once the gush happens...
Remove top bolt. Take cover off.

Now clean the surface of axle and cover with a rice cake on a die grinder.

Get a gasket to match your axle.

Now once this has completey drained or you've jacked it high enough to not allow any residual gear lube to ooze on your gasket and surface...

Put a bead of rtv (blue or black is fine) on the axle housing.
Put same bead on diff cover. Press gasket on cover....now lift cover and place on housing while starting a bolt or two.

Tighten in a criss cross pattern. It will take a while to do this tightening process correctly. Dont rush it.

Done.

Fill with Mobil 1 75-90

You will never leak there again if done properly and you can keep your tough cover.
 
As someone who was in your boat not too long ago this last summer, 5 diff fluid changes later (all different diffs) all I have to say don't worry about the gasket, just rtv will do fine, or just felpro, don't get lubelocker for this. I also wouldn't worry about torquing the bolts to spec, I've never used anything bigger than a 3/8ths drive, tightened them until snug and gave them a double check going along with the 10 point pattern.
What do have against Lubelocker?
I've reused mine several times without any leaks.
 
What do have against Lubelocker?
I've reused mine several times without any leaks.
To clarify lubelocker is basically the go to for most people, it's just overkill and a little pricey for a diff, compared to a dash of rtv or a cheap felpro. I do have a lubelocker for the 42rle tranny pan waiting to go. Unfortunately I don't have any heated spaces to work, and I'm using a bit of rtv as well which needs 70 degrees for 24 hours to cure.
 
What do have against Lubelocker?
I've reused mine several times without any leaks.
I have a Lubelocker on my rear Dana 44 but I could never get one to seal on my front Dana 44. It always dripped 2-3 drops a day. They work when they work but I'm not batting 100% in my uses. I ended up having to RTV my front cover to get it to seal.
 
I appreciate all the advice. Thank you! I think I can do this!

I have my supply list and will order everything I need from Amazon.

Brake Cleaner
2 quarts Royal Purple 75W-90 Gear oil
Quart bottle pump
RTV Blue

I'll get the RDS 6629 Fel-Pro for Dana 44 gasket at the local parts store (because Amazon doesn't have it).

Anything else? Should I do the rear diff at the same time? Does it take 2 quarts of oil, too?
 
I appreciate all the advice. Thank you! I think I can do this!

I have my supply list and will order everything I need from Amazon.

Brake Cleaner
2 quarts Royal Purple 75W-90 Gear oil
Quart bottle pump
RTV Blue

I'll get the RDS 6629 Fel-Pro for Dana 44 gasket at the local parts store (because Amazon doesn't have it).

Anything else? Should I do the rear diff at the same time? Does it take 2 quarts of oil, too?
https://www.amazon.com/dp/B000C2CL2Q/?tag=wranglerorg-20

Idk if that helps but there ya go.

Yes do the rear diff it's probably not far behind. Looks like you got 44 front and rear (lucky 🤠) so everything's the same.
 
If you get stuck give me a call I will come over and give you a hand phn number is above in a post. I f you decide to use the Fel Pro Do not use the RTV with it. Would be good idea to the back although I thing the Dana 44 has a Drain plug located under the axle housing it would just be a basic oil change wont need to pop diff cover to do it if its got the lower drain plug, my buddies rubi had drain plugs my X does not
 
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does the 44 have lower drain plugs
Im assuming op has a rubi or the PO did axle swaps in either case I have an LJ with the 44 rear there is no drain back there just fill. I dont know where the fill or drain is on op's rockcrushers. On my LJs 44 its located about this high on a stock cover. I pulled this off my bonestock jeep because like an idiot I bought a whole new replacement cover thinking the old was too rusty. It wasnt until after i ground it down did I realize.

IMG_20210214_222031_3.jpg
 
If you get stuck give me a call I will come over and give you a hand phn number is above in a post. I f you decide to use the Fel Pro Do not use the RTV with it. Would be good idea to the back although I thing the Dana 44 has a Drain plug located under the axle housing it would just be a basic oil change wont need to pop diff cover to do it if its got the lower drain plug, my buddies rubi had drain plugs my X does not

Thanks! I'll keep it in mind and probably refer back to this thread often when I'm doing the job!

I looked at the rear diff and it does have a plug at the bottom. It looks like I would need a square bit to open it though. There is a little oil staining on the outside of the rear diff so I'll probably replace that gasket, too. I'll judge that by how smooth the front one goes!
 
Im assuming op has a rubi or the PO did axle swaps in either case I have an LJ with the 44 rear there is no drain back there just fill. I dont know where the fill or drain is on op's rockcrushers. On my LJs 44 its located about this high on a stock cover. I pulled this off my bonestock jeep because like an idiot I bought a whole new replacement cover thinking the old was too rusty. It wasnt until after i ground it down did I realize.

View attachment 226456
My buddies Rubi has drains and My 44 out of an LJ does not
 
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If you get stuck give me a call I will come over and give you a hand phn number is above in a post. I f you decide to use the Fel Pro Do not use the RTV with it. Would be good idea to the back although I thing the Dana 44 has a Drain plug located under the axle housing it would just be a basic oil change wont need to pop diff cover to do it if its got the lower drain plug, my buddies rubi had drain plugs my X does not
I completely disagree with using just a fel pro.

We've changed countless of diff gaskets over many years and trust me when I tell you making a sandwich with the rtv and fel pro in the middle...

Will never ever leak. Ever. "
***

Provided one thing...

The fasteners must get tightened appropriately. Which takes time.

Good luck.
 
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I completely disagree with using just a fel pro.

We've changed countless of diff gaskets over many years and trust me when I tell you making a sandwich with the rtv and fel pro in the middle...

Will never ever leak. Ever. "
***

Provided one thing...

The fasteners must get tightened appropriately. Which takes time.

Good luck.
The data sheet from Fel Pro and I called them about this says the use of Sealant will cause the gasket to fail. Feel free to give them a call and verify. Their instructions are very clear on this the Gasket must be installed dry andt hats the reason why fastners need to be torqued to spec anyone that says different is a fool