I spent the last few days sorting out my front diff issues. I pulled the cover and found it to be some kind of thicker "upgrade" cover held on with an entire thing of rtv.... It took forever to get it off.
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I sprayed out the case and the gears all look good and there was no metal so I think it's all OK. I did however notice light shining through the back of the diff... Turns out I had no vent tube anymore. I went ahead and ordered the proper size socket for the pinion nut (1 1/8"), a 1/8th npt tap and fitting to replace the missing vent, some fuel line for the vent hose, and a small filter for the top of the hose (the filter had to match everything else). That all arrived today from Amazon.
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After tapping the vent and replacing the pinion seal, I ran the vent hose and put everything back together. It was a very straight forward and easy repair. It's now all back together and doesn't seem to be leaking. The yoke had a groove worn in it where it contacts the seal so that will probably need replaced at some point.
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Tomorrow I will confirm it doesn't leak at highway speeds, then put the front driveshaft back on and finish prep for the Iowa All Breads Jeep show this weekend!
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Side note: I hate having to clean up the huge mess after such a simple job..
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Sent from my HTC U11 using Tapatalk