Front diff. throwing out lube
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New User
Joined: Mar 2003
Posts: 6
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Front diff. throwing out lube
I have a 91 awd extended aerostar,it keeps throwing lube out
of the front diff. breather tube. It has about 125k miles on it.
It has been doinging this the last 75k miles. I have raised the end
of the breather tube as high,as I can,no change.It makes a bad smell,as the lube ends up on the muffler system.I am worried
about losing the diff. so try to keep,lube at least a half inch
below the fill plug level. So far I haven't lost the diff. Any suggestions what is the problem? Local dealer is no help,bring
it in,basic $95 inspection fee,no promises!
of the front diff. breather tube. It has about 125k miles on it.
It has been doinging this the last 75k miles. I have raised the end
of the breather tube as high,as I can,no change.It makes a bad smell,as the lube ends up on the muffler system.I am worried
about losing the diff. so try to keep,lube at least a half inch
below the fill plug level. So far I haven't lost the diff. Any suggestions what is the problem? Local dealer is no help,bring
it in,basic $95 inspection fee,no promises!
Hotshot
Joined: Aug 2002
Posts: 12,679
Likes: 15
From: BC, Canada
Front diff. throwing out lube
Hi Thos and welcome to FTE 
TSB 98-23-3 talks about your problem. It says to replace the front diff cover with a revised one. I've also used a Dodge anti-foaming
additive with good results too. I dont have the part number but a good Dodge dealer should be able to help you.
The TSB is as follows......
LIGHT TRUCK: 1990-97 AEROSTAR
ISSUE:
Front drive axle fluid may leak out of the vent under some driving modes on some vehicles. This may be caused by the design of the vent.
ACTION:
Install a revised front axle cover assembly which incorporates a baffled vent and plug the original vent. The service procedure is detailed in the Instruction Sheet included in the Axle Cover and Baffle Kit.
The Axle Cover and Baffle Kit (F79Z-4033-AA) includes the following:
One (1) Baffled Cover
One (1) Vent Hose
One (1) Plug (for original vent)
One (1) Instruction Sheet
PART NUMBER PART NAME
F79Z-4033-AA Axle Cover And Baffle Kit
OTHER APPLICABLE ARTICLES:
NONE
WARRANTY STATUS:
Eligible Under The Provisions Of The Basic Warranty Coverage
OPERATION DESCRIPTION TIME
982303A Install Front Axle Cover Kit 1.3 Hrs.
TSB 98-23-3 talks about your problem. It says to replace the front diff cover with a revised one. I've also used a Dodge anti-foaming
additive with good results too. I dont have the part number but a good Dodge dealer should be able to help you.
The TSB is as follows......
LIGHT TRUCK: 1990-97 AEROSTAR
ISSUE:
Front drive axle fluid may leak out of the vent under some driving modes on some vehicles. This may be caused by the design of the vent.
ACTION:
Install a revised front axle cover assembly which incorporates a baffled vent and plug the original vent. The service procedure is detailed in the Instruction Sheet included in the Axle Cover and Baffle Kit.
The Axle Cover and Baffle Kit (F79Z-4033-AA) includes the following:
One (1) Baffled Cover
One (1) Vent Hose
One (1) Plug (for original vent)
One (1) Instruction Sheet
PART NUMBER PART NAME
F79Z-4033-AA Axle Cover And Baffle Kit
OTHER APPLICABLE ARTICLES:
NONE
WARRANTY STATUS:
Eligible Under The Provisions Of The Basic Warranty Coverage
OPERATION DESCRIPTION TIME
982303A Install Front Axle Cover Kit 1.3 Hrs.
Postmaster
Joined: Apr 2001
Posts: 3,818
Likes: 3
Front diff. throwing out lube
If you have your vehicle serviced at 'Quickie Lube' type facilities, there is a possibility they may refilled it with hypoid gear fluid
rather than automatic transmssion fluid that is supposed to be used in the front differential.
rather than automatic transmssion fluid that is supposed to be used in the front differential.
Thread Starter
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New User
Joined: Mar 2003
Posts: 6
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Front diff. throwing out lube
Thank you for the posts,I have ordered the diff. new type vent
kit. ($157)It has been filled with hypoid lube,since I bought it used with 50k miles on it! I guess thats why I have not,lost the
diff. I will clean out the hypoid,and refill with ATF . I am lucky
as I own a frame lift rack and do not have to lay on my back,
while I am cleaning this mess out. I have to clean the muffler system also. It's a4.0 liter v-6,very low on power now.I hope when, I replace the two small cats my power will return again!
Thos
kit. ($157)It has been filled with hypoid lube,since I bought it used with 50k miles on it! I guess thats why I have not,lost the
diff. I will clean out the hypoid,and refill with ATF . I am lucky
as I own a frame lift rack and do not have to lay on my back,
while I am cleaning this mess out. I have to clean the muffler system also. It's a4.0 liter v-6,very low on power now.I hope when, I replace the two small cats my power will return again!
Thos
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