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New 80, New Problems -((



How come they do that? Usualy I filled until the oil apears on the
entrance... Not just "by numbers".
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Just picked up a new 80 (see sig) from another list member who very
kindly got a friend of his (who runs a Porsche garage) to do a full
service replacing all the fluids and filters in the engine, auto box,
transfer case, diffs, etc a couple of weeks ago.
I picked the car up from Edinburgh on Saturday and then drove it the
400 odd miles back home and soon noticed noise/vibration coming from
the back end that appeared to increase the further I travelled.
On Sunday I had a chance to poke around, and it appears that during the
service they only put 2litres of oil in each diff when it should be 2.
6l in the front and 3.2l in the back.
I drained the rear diff oil and it is pretty black, so I get the
impression that the lack of oil in the diff has caused the seals to
overheat and fail resulting in bearing grease in the oil.
The rear is a lot quieter now that it has the correct amount of oil in
it, but am going to replace the bearings and oil seals because there is
still a fair amount of noise and vibration coming through particularly
from the left hand side (also at 123k miles it is still on the
Any pointers/gotchas to watch out for before pulling it all apart?
Julian Voelcker
Mobile: 07971 540362
Cirencester, United Kingdom
1994 HDJ80, 2.5" OME Lift, ARB
Hi Vitor,
They obviously didn't read the manual in the glove box.
The PO is feeling really guilty about this particularly since it was
done by a friend.
Julian Voelcker
Mobile: 07971 540362
Cirencester, United Kingdom
1994 HDJ80, 2.5" OME Lift, ARB
Hi Julian,
My Pro Comps make a very faint noise that had me worrying my bearings
were shot ... Including sounding worse round bends as the rubber is
working harder.
I thought contaminated diff oil went grey / dark green rather than
black? Maybe the oil the dealer put in started out black? I've heard of
bright red and green so why not black?
Best Regards,
Hi Jon,
No, this is a definite grating noise that is separate to the noise of the
MTs that change their tune according to the road surface.
I suppose it is more grey than actually black. The darker colour appears
to be settling out a bit as though it is in suspension, unless it is just
the light from the top of the see through container that it is in.
Julian Voelcker
Mobile: 07971 540362
Cirencester, United Kingdom
1994 HDJ80, 2.5" OME Lift, ARB
Hello guys,
As for the colour, if it's EP90 it should be yellow (red is reserved for ATF,
isn't it?). Green is the colour of some other stuff they alternatively put in
the diffs (can't remember the name).
It makes me wonder - if the diffs were filled 2/3 with the right type of oil
they might just get hotter but they should not break down and shed metal bits.
Maybe the bearings/diffs were a bit shot and the mechanics did not spot it?
Once Julian gets them apart more clues will be available, I hope.
London UK
'92 HDJ80
Quoting Julian Voelcker <[Email address removed]>:
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On 31 Aug 2004 at 10:22, Julian Voelcker wrote:
I would be surprised that 1/3rd less would cause such catastrophic would be no different than running serious off-camber
for a long or heavy stretch....
Or uphill, for that matter, from the viewpoint of the pinion gear.
Also note that leaking knuckles normally means that diff-oil-level is
lowered too, and I can't remember failures of diff's in those
scenario's, only failure of knuckles/birfields, over time.
Willem-Jan Markerink
The desire to understand
is sometimes far less intelligent than
the inability to understand
<[Email address removed]>
[note: 'a-one' & 'en-el'!]
Hi Willem-Jan,
I get the impression that the seal has gone between the greased
bearings and the rest of the diff, causing the grease to flow out of
the bearings into the diff.
Looking through the archives other people have noticed this happening,
however with little damage being because the oil level was sufficiently
high to keep the bearings lubed.
Since the oil level was too low, the bearings weren't being lubed which
I think may have caused damage within 400 miles of driving.
I am going to open up the axle tonight, but suspect reasonable damage
because the bearing is very noisy.
Julian Voelcker
Mobile: 07971 540362
Cirencester, United Kingdom
1994 HDJ80, 2.5" OME Lift, ARB