TXT eating rear differential cover from inside

[wingmanchris]

This mornings project was to swap out the axles, seals, bearings and drums on my 2007 TXT. Upon removing the rear diff cover, I found that the large gear has been rubbing against the inside of the diff cover for some time. Never heard or felt it when driving. Of course there is a lot of metal in the rear end oil and all throughout the differential. I’m spraying it all out with brake cleaner and after getting a replacement cover, will refill it and see how it does. What would cause this to happen? I know the tolerances are tight and the cover sits very close to the hear, but what would cause it to lose that tolerance space? The cover is not dented in from the outside. There wasn’t a gasket on the cover, just permatex. Could that be the issue?

[Farrier]

Looks to me like some part of your diff broke off a chunk of steel from somewhere, got caught in the ring teeth, then wore the grooving into the cover until the chunk ground itself into oblivion

[Scott quail]

There is no gasket there. Just permatex which is normal.

[DaveTM]

Originally Posted by Farrier

Looks to me like some part of your diff broke off a chunk of steel from somewhere, got caught in the ring teeth, then wore the grooving into the cover until the chunk ground itself into oblivion

^^^^------Yeah, what he said-----^^^^

[Sir Nuke]

once you have everything cleaned out....then have swaped out the axles, seals, bearings and drums.....put the cover back on DRY....then trun the axels to see if there is any contact....if there is you could easily hear it. if there isn't and, you are good to go. IF there is any contact....as looking at the pictures the contact is very slight....just get a piece of gasket matirial which will give you the tiny bit of extra space.

[wingmanchris]

Yeah, I put the cover back on after cleaning it all up with no gasket or sealer and it cleared fine. I think like Farrier said, a piece of something was grinding around in there for awhile. From what I can see, everything looks fine and feels fine, it turns smoothly and quietly. I’m going to replace the cover, fill it with oil and keep an eye on it.