Leaky front differential - Arctic Cat Prowler Forums: Prowler UTV Forum
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post #1 of 39 (permalink) Old 09-08-2014, 10:37 AM Thread Starter
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Leaky front differential

My front diff has had a slow leak for quite some time. I just checked the level again, and it really hasn't lost much fluid. About a second after I added to the fill hole, it started coming out the oil fill level hole. I've looked it over and don't see any cracks. It seems to be coming from the between the two halves, so I figure it's a gasket issue. Tried torquing down the bolts, but they are pretty tight. Aside from taking it out, tearing it apart and replacing the gasket, is there a stop-leak product that I might try first? At this point it's just an annoyance, but want it fixed.

Thanks
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Ron

2011 HDX 700 (sold) - CoolFlo windshield, brush guard, Warn winch, hard top, Clarion CD player, amp, Kicker speaker bar, AC rear view mirror, AC storage bag, auxiliary battery with crossover, GBC Grim Reapers.
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post #2 of 39 (permalink) Old 09-08-2014, 10:57 AM
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Are you over filling? My service manual says fill to 1 inch below fill plug threads.
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post #3 of 39 (permalink) Old 09-08-2014, 11:47 AM Thread Starter
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Quote:
Originally Posted by AZGuy View Post
Are you over filling? My service manual says fill to 1 inch below fill plug threads.
I don't think that is the problem. There are two plugs on the side, one is the fill hole and the other says "oil level". I took them both out, then added in the fill hole until it ran out of the "oil level" hole.
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Ron

2011 HDX 700 (sold) - CoolFlo windshield, brush guard, Warn winch, hard top, Clarion CD player, amp, Kicker speaker bar, AC rear view mirror, AC storage bag, auxiliary battery with crossover, GBC Grim Reapers.
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post #4 of 39 (permalink) Old 09-08-2014, 02:53 PM
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Quote:
Originally Posted by Sockman View Post
I don't think that is the problem. There are two plugs on the side, one is the fill hole and the other says "oil level". I took them both out, then added in the fill hole until it ran out of the "oil level" hole.
years ago arctic cat had a bulletin out to fill 1'' below fill hole.dont sound like is why yours is leaking,I would not add any kind of stop leak.take and rough up where it is leaking and run you a swipe of jb weld where it is leaking at and let it set a few days,,,,,Pretty sure that will keep it from leaking,or you can tear it apart and install a new gasket,I had a leak between the two engine cases where the gasket is i fixed it with jb weld and still dont leak a drop and thats been 3 years ago...............I also just fixed a leaking base gasket on a Quad and fixed the problem.

2015 A/C Sport,With a few add ons..........
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post #5 of 39 (permalink) Old 09-08-2014, 04:33 PM Thread Starter
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That's not a bad idea. I'll probably try that.

Checked out the part diagram and it doesn't really have a gasket, just an o-ring. I don't know if stop-leak would work for that anyway.
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Ron

2011 HDX 700 (sold) - CoolFlo windshield, brush guard, Warn winch, hard top, Clarion CD player, amp, Kicker speaker bar, AC rear view mirror, AC storage bag, auxiliary battery with crossover, GBC Grim Reapers.
2007 Suzuki Eiger
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post #6 of 39 (permalink) Old 09-09-2014, 11:55 AM
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Quote:
Originally Posted by Sockman View Post
That's not a bad idea. I'll probably try that.

Checked out the part diagram and it doesn't really have a gasket, just an o-ring. I don't know if stop-leak would work for that anyway.
Give that a try and see what it does ....just might keep you from tearing it apart.

2015 A/C Sport,With a few add ons..........
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post #7 of 39 (permalink) Old 03-17-2015, 08:28 PM Thread Starter
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Replaced the axle seals tonight. What a PITA it is to remove the axles on this unit. COuldn't do it by myself, had to have a friend help with the push/pull. Will see if that fixes my leak.

Ron

2011 HDX 700 (sold) - CoolFlo windshield, brush guard, Warn winch, hard top, Clarion CD player, amp, Kicker speaker bar, AC rear view mirror, AC storage bag, auxiliary battery with crossover, GBC Grim Reapers.
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post #8 of 39 (permalink) Old 03-17-2015, 11:02 PM
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My front diff was leaking, when I had it rebuilt there was a hairline crack so the dealer JB welded the crack and around it. Hasn't leaked a drop since.

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post #9 of 39 (permalink) Old 03-18-2015, 07:11 AM Thread Starter
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Quote:
Originally Posted by 4508js View Post
My front diff was leaking, when I had it rebuilt there was a hairline crack so the dealer JB welded the crack and around it. Hasn't leaked a drop since.
Interesting. I was going to try this before taking the front diff out. Another member said these are notorious for those seals going bad. I couldn't really tell for sure since I had to pretty much destroy them to get them out. I can't see the source of the leak. Hopefully this does it. If not, it'll have to come out and I'll get a real close look.

Ron

2011 HDX 700 (sold) - CoolFlo windshield, brush guard, Warn winch, hard top, Clarion CD player, amp, Kicker speaker bar, AC rear view mirror, AC storage bag, auxiliary battery with crossover, GBC Grim Reapers.
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post #10 of 39 (permalink) Old 03-18-2015, 07:25 AM
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I'm going on 6,000 miles plus and I have not had any differential leaks yet! I did add additional bladders to both the front and rear diffs. , not sure if it helps but can't hurt! I took one bladder off after a ride, damn I didn't think it would ever quit spouting hot lube! Trace amounts show up after a really hard ride, but no drops on pavement. I think over filling is the main cause for leaks. Some have added a catch can breather setup to the rear.

2009 700EFI XTX, , AC Winch, 2010 Dust Shield EPI Sport Utility Clutch Kit , Street Legal, Cage chopped 2 ", Aluminum Diamond Plate Trim, Relocated Factory Bladders with covers, 5 Pt. Harness installed, Bed Tiedown System, Scat Pro-Car Seats, Secondary Battery installed, Oil Pressure, Oil/CVT Temperature, Volt Meter & Water Temp Gauges installed with Dash Plate, Bighorns, ITP Black 212 Wheels. Tonneau cover. 750 Big Bore Kit, Web Cam, and Rocker Arms.

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