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Front diff fluid loaded with metal pieces (too many to count)

Keelay

By Keelay
in Ask A GM Technician

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Keelay Enthusiast

Keelay

Posted
Posted

Hi there,

 

I have posted a few times about the problems with my 2011 Chevrolet 2500HD. I have had the front differential rebuilt twice now in the last 10k miles. The last rebuild was on 2/8/13.

 

I decided to check the fluid today (3/14/13) after hearing significant noise in the front end (same reason I brought it in and failure was discovered twice before) as well as a significant heated oil smell coming up through the cab of the vehicle in 4WD.

 

I took off the fluid check/fill bolt and grabbed a sample of the fluid. It was littered with metal. Small pieces, larger pieces, literally thousands of them in the tiny sample I have. When I wiped my hands on a rag, all I could see was silver shavings.

 

My question is does this mean the differential has issues that remain after this second rebuild? I have maybe 300 miles on the truck in 4WD since the last rebuild and the noises in the front end (in 4WD) are more profound than ever.

 

I am a little weary about bringing the truck back to the dealer and asking them to fix it a mere month after it was just rebuilt, however it is still under warranty.

 

Does this seem strange?

Jsdirt Senior Enthusiast

Jsdirt

Posted
Posted

Why be weary? Bring it back and DEMAND they fix it CORRECTLY.

Keelay Enthusiast

Keelay

Posted
  • Author
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The only reason I am weary is the fact that the truck has just gone through the state of New Hampshire lemon law hearing and the arbitration board ruled in favor of GM. I am appealing that decision because the board never inspected the vehicle (they took it for a test drive).

 

The hearing was 3 days ago, and I checked the fluid because I was so pissed at the outcome and lack of any form of inspection done by the arbitration board. Regardless, I am wondering if this fluid contents means that the differential has in-fact gone bad again, or could be considered a sign of "normal" wear.

Doug_Scott Senior Enthusiast

Doug_Scott

Posted
Posted

If they have rebuilt it twice, and now it needs a third rebuild, you may want to sit down with the service manager and have a polite, calm conversation with him. If it keeps talking the same parts out, then they have not fixed the actual cause. Sounds more like they are treating the symptoms.

 

It is likely time to bring in the GM area service rep for a consult as well.

 

Having metal shavings suspended in the oil is telling you something is coming apart. Do you know what parts they replaced last time, or the time before? Did they find out last time where the metallic shavings came from?

 

One thing to keep in mind, do not start out demanding anything. Demands are something you build up to, not what you start with. Treat them like you expect to be treated, That being said, you also need to fully understand what they are saying and doing. Do not be afraid of asking them to explain stuff you don't understand. Take notes, lots of notes.

NitroCherokee Enthusiast

NitroCherokee

Posted
Posted

Why are you driving in 4WD so much? I live in Michigan and have 80,000+ miles on my truck and I can gaurantee it hasn't seen 300 of them in 4WD I would bet not even 100

DaveH71 Enthusiast

DaveH71

Posted
Posted

What are your driving habits when in 4wd. How fast are you going? A lot of turns? Why the need for 4wd so much?

NitroCherokee Enthusiast

NitroCherokee

Posted
Posted

I doubt it is his fault. See if they'll replace the whole axle.

300 miles in 4WD in just over a month, I'm thinking it may be. Unless he is an Ice Road Trucker I haven't seen any weather in the lower 48 that would require that much 4WD driving

kstruckcountry Senior Enthusiast

kstruckcountry

Posted
Posted

I would be more concerned with what he was doing in 4x4 than the distance. My old truck had a lot of miles on the 4x4 and had no issues. And yes 300 mi in a month seems far...

Keelay Enthusiast

Keelay

Posted
  • Author
Posted

Vehicle is a plow truck in NH, we have gotten quite a bit of snow this year thus the mileage requiring 4WD is a little higher than average.

 

I have spoken with the GM rep, they have denied a further issue on multiple occasions. Dealer where the truck was purchased has denied a problem on multiple occasions as well. My lemon law claim was ruled in favor of GM, however I am appealing it on the basis that there was no inspection done to see if the differential was failing.

 

Unfortunately I am not sure what I can actually do at this point, aside from wait out the appeal and presume that if I get it fixed I am voiding my Lemon Law claim. The NH state Lemon Law process is a joke.

NitroCherokee Enthusiast

NitroCherokee

Posted
Posted

Take it to another dealer, if you are sure you are not tearing it up plowing in 4WD making tight turns when the tires are not able to slip then whoever has been "rebuilding" it isn't doing something right. I built litterally hundreds of differentials and never had one fail that wasn't abused beyond it's capabilities

Beer Belly Enthusiast

Beer Belly

Posted
Posted

Might be a stupid question.....Why does it matter how many mile he drives in 4WD ???....is there a life expectancy on the 4WD system ??

Doug_Scott Senior Enthusiast

Doug_Scott

Posted
Posted

Might be a stupid question.....Why does it matter how many mile he drives in 4WD ???....is there a life expectancy on the 4WD system ??

 

I would imagine the intent of the question was more in line with how many miles do you drive in 4wd on dry paved roads. Driving in 4wd on dry paved roads is tough on the truck. Unless all 4 tires are exactly the same circumference, and the road is dead straight, driving in 4wd will create large torsional loads on the truck. When on wet or non-paved roads, the tires will just slip to relieve the torsional load.

Beer Belly Enthusiast

Beer Belly

Posted
Posted

I would imagine the intent of the question was more in line with how many miles do you drive in 4wd on dry paved roads. Driving in 4wd on dry paved roads is tough on the truck. Unless all 4 tires are exactly the same circumference, and the road is dead straight, driving in 4wd will create large torsional loads on the truck. When on wet or non-paved roads, the tires will just slip to relieve the torsional load.

I would hope the 300 miles would be justified for 4WD, but I guess you can't assume

Jsdirt Senior Enthusiast

Jsdirt

Posted
Posted

No metal chunks with mine (yet) .... but using 4x4 only during slippery conditions or on dirt roads, the drivers side of the diff started leaking where the CV axle output is, at only 50k miles. More than likely a bearing is failing .. unless they just used crappy seals .. but the amount of up/down play tells me otherwise.

 

Even my old first gen S10's never had this issue in 2 decades & 200k plus miles ...

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