My 5 speed GV's  front diff just started leaking recently on the passenger side.  It's a pretty good leak.  I know this is a common problem with the design, but I guess I can't complain.  After all, I've got 130,000 miles on it.  So....here's the situation/questions.  WARN hubs are being put on right now.  This should stop the front axles from spinning, and hence slow down the leak, right?  Second, I want to do the conversion to the Sidekick diffs with the 5.125 ratio in the future.  I'll be keeping the GV's steel carrier case and axle housing.  Will this eliminate the leak, or  does the problem relate to the housing?  The axle seal is in the diff, right (not the housing)?  Has anyone seen the technical service bulletin on this diff problem?  Thanks in advance for the info.  Looks like I won't be using 4WD anytime soon

You need to replace the seal on the end of the housing where the axle goes in .  The part is like $2 but it's a pain in the a$$ to pull that shaft out to replace the seal.  The only other issue that I know of with front diff's is for the oil level on 99-02's which to fixyou should jack the front end up like 30 deg. then fill the diff.

George

So swapping diffs won't fix the leak, right?  You're saying the seal is actually on the end of the axle housing?  Thanks.

My front differential carrier wore out where the RH output shaft rides.  Output shaft was also worn.  The excessive clearance caused the premature seal failure.

Suzuki fixed under goodwill warranty extension, I only paid labour.

After seeing the removed parts, I highly doubt only replacing the seal will provide anything but a short term patch up.  Adding locking hubs to disengage would probably help, though.

If you have this type of leak, this would be a "cheaper" time to install a locker.

Marc

front diff's is for the oil level on 99-02's which to fixyou should jack the front end up like 30 deg. then fill the diff.

George

fill 0,2-0,3 litres more than FSM say. that makes it 1,2-1,3L in the diff

Sorry to go way back in time and revive this thread but I now have a worn front diff. I went to the suzuki dealership to pick up the seal. The guy said he's seen a lot of front diffs replaced at the cost of approx $1000 for parts and $1000 for labor!!!! Is that true? If so I need to get creative because I won't spend $2K on my front diff. I'd rather sell my vit and get one with lower K's or something. Anyway, what is the real solution to this problem? Who has gone through this experience?

Fixing the seal isn't all that hard. Can be done with hand tools in a couple hours as a newbie.

Yeah I'm not worried about replacing the seal, I'm worried about the diff being worn. If your seal has leaked in the past try this: grab the axle on the passenger side right where it goes into the diff, try and move it back and forth, any slop? mine has a bit and that is what the dealer was talking about when they said they have rebuilt a number of diffs. Anyway, as it turns out I had a mechanic look at it and he said mine seems fine, he thinks the diffs are being rebuilt because the worn seal causes the diff to run low on oil of which mine is not (and according to him my slop/play isn't that much = I'm a bit paranoid). He also said my seal is still OK as it is only "seeping" and not leaking (IE no oil has leaked to the bottom of the diff and it's not even wet oil)

i've had my diff opened by the dealer under warranty more than once, always seems to have a bit of play in the axles.

Yeah....my front diff was just done.  Had play in the passenger axle before the work was done, and still has it.  I think it's normal to have a little bit of in and out movement.

so now i'm curious, what are the symptoms to needing a new diff? if the dealer is right and it costs $2000 then i dread the day I'll need it repaired. what did it cost you guys?