02 660 Grizzly rear diff leak

[havoc2000]

Hey everyone.Have an 02 660 Grizzly.Had an oil leak at the rear diff, right behind the brake caliper.Obviously from the oil seal, or so I thought.I bought and installed a new seal, put the rear end back in, and still a leak.It only leaks in reverse, nothing in forward.I believe the gear is shaped so that the oil is drawn to the seal in reverse.Any ideas on this ? I see no other seals in that area in the exploded diagrams.I guess I am going to have to rip it apart again, but it's getting old.Any suggestions ?

Ok, more info. I just took another look.It still has the rear end up on jack stands, and I filled the diff with oil until it was running out of the fill hole.I am wondering if maybe the rear being raised up is causing the already overfull oil level to run out of the front seal.Maybe not, I would think it would take more than that, but the seal isnt designed to hold pressure, and it seems that in reverse, obviously it pushing the oil to the seal, and since it's not even close to level, the excess oil is leaking out.Maybe it'll stop if I drain a bit off and try it again once level.Still open to ideas....

 

[gunny]

Yeah Havoc2000, when ya fill the diffs, have the bike level. Any over fill will build up pressure & the seal is the weak link, so it leaks out.

Hope ya got it fixed.

Later ...

 

[grizztracks]

Most all differentials have a vent tube to prevent pressure build up. Check your vent tube and also the port connection at the top of the diff. Any blockage will cause seals to leak.

I don't want to doubt your abilities but did you put the seal in right? The spring side in, squared with housing, checked seal surface for grooving. I like to put silicon sealant on the outside of the seal and a little lube on the seal and yoke before reassembly. Seals sometimes get damaged. I've even seen the spring pop out when driving them in. Just a few ideas. good luck.

 

[gunny]

Most all differentials have a vent tube to prevent pressure build up. Check your vent tube and also the port connection at the top of the diff. Any blockage will cause seals to leak.

I don't want to doubt your abilities but did you put the seal in right? The spring side in, squared with housing, checked seal surface for grooving. I like to put silicon sealant on the outside of the seal and a little lube on the seal and yoke before reassembly. Seals sometimes get damaged. I've even seen the spring pop out when driving them in. Just a few ideas. good luck.

GrizzTracks ... you is so right ... totally forgot about the vent ... and ya still don't want to overfill the diff ... but check that vent ... it might even be pinched someplace ...

Let us know if ya got the leakage fixed and what ya did to correct it.

Later ....

 

[grizztracks]

just one more thing to check. A bad pinion bearing will also cause the seal to leak. If you tear it down again check for play.

 

[havoc2000]

I fixed it! I ended up tearing the rear end out again, and found that the seal had gotten punctured somehow.I put in a new one again, and it's all set now.I am so glad I finally got off my duff and fixed it.Thanks for all your ideas, folks! Time to ride!

 

[grizztracks]

Good to hear your running again. Installing seal can be difficult especially when their in awkward places.