Front diff full of metal

[sdhammond]

Found a lot of metal in the front diff fluid at 10k miles. One piece is 1"x 1/4". Ineos is literally telling it is fine as long as the fluid is full and there are no odd noises. ARE YOU KIDDING ME Ineos?
Anyone else have this problem and have Ineos tell them it is OK?

 

[Logsplitter]

Found a lot of metal in the front diff fluid at 10k miles. One piece is 1"x 1/4". Ineos is literally telling it is fine as long as the fluid is full and there are no odd noises. ARE YOU KIDDING ME Ineos?
Anyone else have this problem and have Ineos tell them it is OK?

I hope you documented it with some photos

 

[Glen]

@sdhammond - You’ve provided two dimensions for the piece of metal . . . what’s the third dimension? Was your object created by smearing the metal flakes found on the drain plug magnet onto something else?

Without some more information about the metal object you found or some pictures, your report is unlikely to receive much helpful input.

 

[sdhammond]

Most are thin. See the pic. Thanks everyone...

 

[Dokatd]

Most are thin. See the pic. Thanks everyone...

Those look like bits of the casting process. Like they never properly cleaned the housing prior to assembly. If not, your diff is going to like a short life.

 

[C-Mack]

Definitely looks like casting left overs. If you haven’t heard any abnormal noises from the diff at this point you are most likely okay. If it was my rig, I’d fill the diffs back up and run them for another short period of time and drain them again to see if any new swarth shows up. Certainly brings up a question about quality control from the axle supplier though.

 

[holdmybeer]

Service manager commented recently that just a few hundred km past first service, with diff fluid replaced, a diff fluid check showed the fluid was unexpectedly dark. No bits of metal. But ... should I be concerned?

 

[255/85]

Service manager commented recently that just a few hundred km past first service, with diff fluid replaced, a diff fluid check showed the fluid was unexpectedly dark. No bits of metal. But ... should I be concerned?

Likely heat related. Drive a few miles at highway speeds and touch your hand to the center section of the axle assembly in question. If it's uncomfortably hot then the ring & pinion set-up could be off or failing from bearing wear. If it's just mildly warm then it could be contamination from seals or sealant, etc.