I took my '98 expedition to a local indy to have the leaking axle seals replaced.
The axle seals are now fine, but the differential now leaks. Only a few dark drops per night at first, so I took it back to the mechanic, told them what was going on, and they said they would replace the differential seal again. Apparently they had to remove the cover to drain it prior to replacing the axle seals.

Now, after re-replacing the seal, the differential leaks much more. A small puddle of honey-ish oil under the axle. I noticed this after my wife had left for the day. I cleaned it up, had her come stright home and park it. After sitting overnight, there is another small puddle under the axle that is dripping from the differential.

Any thoughts? Is this more than a differential gasket? Did they use the wrong gasket or cover? I did notice the cover was nice and shiny. Either not the same one I went in with, or they spent a lot of time cleaning it.

Thanks in advance!

 

On my '01 there isn't a gasket. It requires using permatex or some other liquid gasket. I believe that I used black.

 

You are correct...no gasket, it calls for silicone.

 

hmm... my "Chilton's" manual says some use a gasket and others use silicone. I ended up going back to the shop for another fix. The mechanic said it needs a "special" gasket. He has one and will put it in. LOL!

This shop was recommended to me by my father-in-law... Come to think of it, his vehicles are always breaking down...

 

It may be your pinion seal. With a 'small puddle' you should be able to crawl under there and see if it is coming from the case cover or the pinion seal (where the driveshaft connects). If your mechanic didn't see the pinion seal leaking, then I'd guess it's not, but it might not hurt to ask.

 

No gasket on my 98 differential cover......Need to let that sealant set up for a few minutes before replacing the cover.

 

Well, the mechanic put the "special" seal on. It appears to be silicone and has held through the night. No additional leaking. Thanks all!