Front diff metal in fluid

[sdhammond]

Huge metal deposits in front diff at 10k miles. Ineos says it is fine as long as there is no noise or problems. Crazy. Anyone else have this problem?

 

[ADVAW8S]

That is why they require us to change the fluid at 10k.

 

[Commodore]

Huge metal deposits in front diff at 10k miles. Ineos says it is fine as long as there is no noise or problems. Crazy. Anyone else have this problem?

Picture? Huge is a mater of perspective… just ask my wife.

 

[Tazzieman]

Picture? Huge is a mater of perspective… just ask my wife.

 

[Jeremy996]

Ineos' response is pragmatic, if it is not whining, then the big bit is not critical. Cracking a diff to look at all of the gears and wearing surfaces is expensive.

 

[NQ94]

View attachment 7919256

Considering every diff issue mentioned on this forum has had complete axle assemblies replaced under warranty I wouldn't be surprised if the dealer is avoiding or pushing out the job because of parts availability.
Simple job to pull the cover and inspect the gears. A piece of metal 1"x1/4" is enough to cause a major failure in any gear train. If it's started dropping metal that size it won't stop making metal until failure and on a 10k mile diff that is unacceptable.

 

[Clark Kent]

1" X 1/4". Is one end shaped into a hex? Where have I seen that recently?

 

[Tom109]

1" X 1/4". Is one end shaped into a hex? Where have I seen that recently?

View attachment 7919258

Another good reason to not stick fake measuring tools in the fill hole!

Fill-n-spill baby…

 

[Logsplitter]

Has anyone measured how much oil it takes to fill to spill ? How much more than 2.1L does it take ?
Any guesses? I’ll guess 2.9L. to 3L. Ineos have said 2.1L for a reason that we are not sure about. I’d be happy if the diff was a 100ml too much but not a litre too much.

 

[Tom109]

I plan to install the Agile cast iron diff covers this Spring. My plan will be to measure how much extra must be added to reach fill-n-spill. Then I’ll keep the fully drained oil for refill with the Agile cover, just to compare full installed volume. After that I plan to fill to the fill hole, hex wrenches be damned.

 

[Greasemonkey]

It holds a little over 3 liters before it overflows. I've tried it myself.

 

[Zimm]

Considering every diff issue mentioned on this forum has had complete axle assemblies replaced under warranty I wouldn't be surprised if the dealer is avoiding or pushing out the job because of parts availability.
Simple job to pull the cover and inspect the gears. A piece of metal 1"x1/4" is enough to cause a major failure in any gear train. If it's started dropping metal that size it won't stop making metal until failure and on a 10k mile diff that is unacceptable.

once they got approval from INEOS, it only took my dealer a week. The approval and all the testing on the other hand was a bit of job.

 

[Logsplitter]

It holds a little over 3 liters before it overflows. I've tried it myself.

If that’s the case, then fill-to-spill is roughly a 50% overfill compared to the recommended volume.
That actually reinforces the point in my mind: INEOS are using that axle in a different application to what it was originally designed for, effectively a generic axle adapted for a specific use.
The Grenadier’s axle oil level has to allow for sustained motorway speeds as well as extreme off-road angles, which the original application may not have been designed around.

 

[sdhammond]

Picture? Huge is a mater of perspective… just ask my wife.

Ineos' response is pragmatic, if it is not whining, then the big bit is not critical. Cracking a diff to look at all of the gears and wearing surfaces is expensive.

Mostly agree but pragmatism is buffered by simple lunacy "if the function is fine then the diff is fine". Sierra Ineos Dealer Service in Orange County CA has largely been a s##t show since they opened. They are attempting to straighten out the service department...

 

[Commodore]

Mostly agree but pragmatism is buffered by simple lunacy "if the function is fine then the diff is fine". Sierra Ineos Dealer Service in Orange County CA has largely been a s##t show since they opened. They are attempting to straighten out the service department...

Is that actually metal? It doesn’t look alike a gear surface. Sorta looks like gasket material. Did it really come out the drain hole attached to the magnetic on the drain plug

 

[Zimm]

Is that actually metal? It doesn’t look alike a gear surface. Sorta looks like gasket material. Did it really come out the drain hole attached to the magnetic on the drain plug

Move it around. It doesn’t reappear to have a machined surface.

 

[sdhammond]

Metal. Both plugs were covered with these pieces. I pulled more out of the dirty oil with a magnet.

 

[Commodore]

Metal. Both plugs were covered with these pieces. I pulled more out of the dirty oil with a magnet.

I would take the diff cover off and check the gears. That said, it doesn’t look like gear or bearing material. If it was you would be hearing it. It looks more like something left behind during manufacturing.

 

[Jeremy996]

Looks like casting flash, (and poor prep). No wonder there is an oil change for the diffs early.

 

[Commodore]

Looks like casting flash, (and poor prep). No wonder there is an oil change for the diffs early.

That’s my thought as well. As long as it didn’t get kicked up into the gears then everything should be fine. I would push the dealer/Ineos to warranty that axle for 100,000 miles.