2019 front differential seal leaking

IIIOIISTER said:

Just for you Don

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Fair enough @IIIOIISTER

sorry about that. It’s been a MO since the TRX was announced to do something similar. Just last week someone posted the exact same thread but was busted when they posted a pic of a regular F150.

IIIOIISTER said:

@JohnyPython I've wiped it off a couple of times and it continues to seep very slowly. Going to call the dealer to see if they can look at it today or next week.

I was under the assumption that the front diff isn't engaged while driving in 2H, which is what I'm in majority of the time (Normal Mode). Unless the torsen diff kicks in at times when the truck "thinks" the rear isn't generating enough torque? I'm sure someone with a 10LB brain can visualize or explain this better.

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Without being the engineer that built it. When it’s it 2wd, only power is transmitted to the rear with no exception. With that said, I don’t believe that the front driveshaft rotates while not in 4h or 4A. @FordTechOne, thoughts?

dirt or grime can get lodged in there but the seal is so thick, it would need to jammed way in there and be of size.

I suspect you have to have it replaced.

do you know if the truck was heavily modded before you bought it?

Donmatteo said:

Without being the engineer that built it. When it’s it 2wd, only power is transmitted to the rear with no exception. With that said, I don’t believe that the front driveshaft rotates while not in 4h or 4A. @FordTechOne, thoughts?

dirt or grime can get lodged in there but the seal is so thick, it would need to jammed way in there and be of size.

I suspect you have to have it replaced.

do you know if the truck was heavily modded before you bought it?

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The truck was bone-stock other than a whole suite of Rough Country behind-the-grill light bar, bumper lights, and tri-fold bed cover.

Only mods I've added are the Eibach coilover springs, Camburg UCA, and Deaver L84 (+3).

IIIOIISTER said:

The truck was bone-stock other than a whole suite of Rough Country behind-the-grill light bar, bumper lights, and tri-fold bed cover.

Only mods I've added are the Eibach coilover springs, Camburg UCA, and Deaver L84 (+3).

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Was it leaking before the suspension changes? Ride height the same? How’s the driveshaft angle? Still under warranty? If so, you might get some grief about aftermarket parts being the cause.

Donmatteo said:

Was it leaking before the suspension changes? Ride height the same? How’s the driveshaft angle? Still under warranty? If so, you might get some grief about aftermarket parts being the cause.

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Suspension only added maybe 2-3” to the front and the truck is leveled.

I only noticed the leak when I went under the truck to admire the awesome plastic oil pan...

IIIOIISTER said:

@JohnyPython I've wiped it off a couple of times and it continues to seep very slowly. Going to call the dealer to see if they can look at it today or next week.

I was under the assumption that the front diff isn't engaged while driving in 2H, which is what I'm in majority of the time (Normal Mode). Unless the torsen diff kicks in at times when the truck "thinks" the rear isn't generating enough torque? I'm sure someone with a 10LB brain can visualize or explain this better.

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Correct, the front differential in not engaged and does not turn in 2WD. This is because the transfer case is disengaged and each Integrated Wheel End (IWE) disconnects the hub from the axle on both sides. Therefore, the Torsen differential is not part of the equation.

2019+ models have a strategy in which the IWEs remain engaged for a couple miles after a cold start to allow the system to warm up and build vacuum. Other than that, the system is fully disengaged the rest of the time. Have you engaged a 4WD mode for any significant amount of time? With such low miles, it’s possible that the pinion seal itself hasn’t fully mated with the pinion flange.

Before taking it in, my recommendation would be to clean the area up very well with brake cleaner and then leave it in 4A for an extended drive, such as on the highway. Then re-evaluate the leak.

FYI, the component you’re seeing on your photos is the pinion seal deflector, not the seal itself. The seal under that deflector mounted in the nose of the housing.

IIIOIISTER said:

Suspension only added maybe 2-3” to the front and the truck is leveled.

I only noticed the leak when I went under the truck to admire the awesome plastic oil pan...

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2019’s don’t have a plastic oil pan. It’s aluminum. So not sure what you were “admiring”.

FordTechOne said:

2019’s don’t have a plastic oil pan. It’s aluminum. So not sure what you were “admiring”.

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Thanks for the pro tips.

1. I'll put it in 4wd and hit up some of the service roads around here.

2. I have a 2018 pre-aluminum pan model, not a 2019. I used "admiring" with heavy sarcasm. The dude that started this post has a 2019.

IIIOIISTER said:

Thanks for the pro tips.

1. I'll put it in 4wd and hit up some of the service roads around here.

2. I have a 2018 pre-aluminum pan model, not a 2019. I used "admiring" with heavy sarcasm. The dude that started this post has a 2019.

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Sounds good. Nothing wrong with the composite oil pan, they actually deaden sound better than aluminum, which is one of the reasons they were used. The issue was the sealing methods that they were using at the plant, which caused poor RTV adhesion and resulting leaks. The process was corrected on the later build models such as yours.

Well, I went for a 40 min drive down a nearby service road on 4H (Normal Mode). Came back, let the truck cool for a bit, only had a tiny bit of leak.

Waited a little longer, and decided to check the front diff fluid level. As soon as I took out the drain plug, it was obvious that the front diff was overfilled, and hasn’t had service done in a hot minute; fluid was dark brown, and I caught about half a qt of it.