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Old 01-26-2006, 08:43 PM
   GM better release a tech bulletin NOW! - Diff Leak Issue
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I got my Solstice in for a leaking differential in the nick of time. Supposedly, my fluid was dangerously low when they serviced it today. Yep, my pinion seal was bad, and I've only noticed leaking for a couple days.

This is a serious issue. My differential was on the verge of running dry. The service department was severely reluctant in releasing the vehicle to me until the part comes in, but I NEED the car... so they put out a spac for the part and it should be in soon.
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Old 01-26-2006, 09:01 PM
  
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I wonder what is causing this problem. Rear ends don't "just" leak. I can't believe it is a manufacturing problem. Design? Bad fitting parts from a supplier?

Did you ever see gear oil in the driveway, or residue beneath the differential housing? Or is this leak completely internal?
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Old 01-26-2006, 09:20 PM
  
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Originally Posted by Fortimir
The service department was severely reluctant in releasing the vehicle to me until the part comes in, but I NEED the car...

With a brand new car in the shop for a lack of parts they should give you a loaner...I'd insist on it and save the rear end from a complete blowout in a bad location.
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Old 01-26-2006, 09:40 PM
  
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Diff is a German part from Getrag. Can't understand why the problems given same part is used in Caddy CTS. Could just be a bad batch from Getrag, who knows.
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Old 01-26-2006, 10:08 PM
  
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What are the symptoms? burning smell? leaks? (obviously, but where exactly would this be?)
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Old 01-26-2006, 10:11 PM
  
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What are the symptoms? burning smell? leaks? (obviously, but where exactly would this be?)
Yea seems like it. Brentil posted a few pics in the diff leak thread. Shows some burnt drips on the exhaust.

Differential Leaks
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Old 01-26-2006, 10:20 PM
  
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I've said it before, and I'll say it again. I believe the problem stems from overfilling the differential at the plant. Plain and simple. For those who don't know overfilling is worse than underfilling. When you overfill your engine with oil, overfill your transmission with trans fluid, or overfill your rear end with lube (get your minds out of the gutter!) guess what happens? I'll give ya two guesses, but the first one doesn't count.

Did you guess that it puts more stress on the seals, and the weakest seal gives way? Congratulations!

The thing is, though, that these differentials have a relief valve designed in. Maybe it's designed as more of a vent than a relief valve, I'm not sure. I've posted pictures of it elsewhere when I discovered that it was the source of my fluid leak. My differential was overfilled significantly, by the way. Regardless of what its purpose is, that is where some of my excess fluid escaped. I was lucky, my car didn't sh*t a pinion seal.

If the differentials are filled at the final assembly plant, then that could be the reason why this problem isn't prevalant on the CTS, to our knowledge.


Here's the scenario I picture... This may be a stretch, and it may not go down just like this, but here goes.

The new guy whose job it is to fill the differential with fluid (or programmed the dispenser to meter the correct volume of fluid) misunderstood the instructions. Maybe he was instructed that "full" is when the case is filled to the bottom of the threads of the fill plug in the casing. That is correct, by the way. In order to check to see if it is full, you jack the car up level, crawl underneath, and remove the fill plug. The fluid should be even with the bottom of the threads.

If the guy that is filling them does so at a bench before the part goes on the car, maybe he is just misinterpreting the directions. Maybe he is filling it up to the bottom of those threads with the differential on it's side

Or maybe I'm just off my rocker
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Old 01-26-2006, 10:37 PM
  
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Hey 2KWK, couple of questions:

I'd like to test the level in my diff. Is the fill plug on the side, if so, is it just a simple pull the plug and check things out, or is it more involved, and I shoudl have the dealer check. Maybe a pic on the forum exists of the drain plug, and you could annotate it for us simpletons. I'd really like to go for the "preventative cure" on this issue, your help would be greatly appreciated (or anyone who can provide the same)

FYI, my mechanical experience is up to pulling a oil drain plug, is that enough???
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Old 01-26-2006, 11:37 PM
  
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Apparently, there is a part re-design (pinion seal) but it is not available yet.

I think someone mentioned it stems from something having to do with synthetic vs. natural lubricant.
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Old 01-26-2006, 11:37 PM
  
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Here ya go. The fill plug is on the driver's side. The drain plug is on the bottom (obviously). Basically, if it is overfilled, just let it pour out of the fill plug hole (into a catch pan, obviously) until no more pours out. You'll need a 10mm allen wrench and the car needs to be level. If yours has been to the dealership already to have the pinion seal replaced, or have the diff checked out, then they should have already corrected the fluid level if it was incorrect.

Also, see page 5-40 in your owner's manual

Edited to correct allen wrench size
Attached Thumbnails
gm-better-release-tech-bulletin-now-diff-leak-issue-diffplugs.jpg  gm-better-release-tech-bulletin-now-diff-leak-issue-fill-plug.jpg  
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Old 01-26-2006, 11:50 PM
  
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Originally Posted by 2KWK4U
Here ya go. The fill plug is on the driver's side. The drain plug is on the bottom (obviously). Basically, if it is overfilled, just let it pour out of the fill plug hole (into a catch pan, obviously) until no more pours out. You'll need an 8mm allen wrench and the car needs to be level. If yours has been to the dealership already to have the pinion seal replaced, or have the diff checked out, then they should have already corrected the fluid level if it was incorrect.

Also, see page 5-40 in your owner's manual

Thanks, that looks pretty easy! Mine hasn't been serviced, so it might be worth checking.
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Old 01-27-2006, 12:05 AM
  
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I would actually like everyone to check theirs. Maybe we can see if they are commonly overfilled. Maybe we can prevent some people from blowing seals unnecessarily (I'm not referring to Navy special forces... minds out of the gutter!)
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Old 01-27-2006, 12:08 AM
  
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Guys... I really don't know if over-filling is the exact cause of this problem. There IS supposedly a part re-design.
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Old 01-27-2006, 12:19 AM
  
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