M190 Front Differential Crack under drain plug

[daniel.edwards2019]

Trying to figure out the best path forward....I was servicing my differentials and my transfer case. I have a 2023 Ford Bronco Big Bend Non Sas with an m190 FDU.

Long story short there were no issues with servicing the FDU removed the drain and fill plug, replaced the fluid, and then applied the high temp thread sealent and torqued to 20 FTLB. After cleaning up I noticed some gear oil residue forming into a drop on the bottom directly below the drain plug but not on the side face. I though I missed some of it so I wiped it off and checked a few minutes later and it was there again and thats when I noticed the hair line crack....idk what to do or best path forward...any advice would be welcome.

Sponsored

 

[daniel.edwards2019]

Here are some photos also do you think its safe to drive and anyone have any idea for the cost for a replacement?

 

[2023bronco]

Safe to drive. Will need to be drained to repair. Housing can be weld repaired.

 

[Brian_B]

As long as it has fluid it’s ok to drive on. And you could probably clean it up and seal it over temporarily with some RTV or something.

The bad news is it will only get worse over time, and that isn’t a permanent fix

Replacement - I bet there are more than a dozen around these forums that you could find a takeoff for a reasonable cost.

 

[Brian_B]

Also if you are still under warranty that may get covered - maybe even the 5/60k powertrain?

 

[daniel.edwards2019]

Its a 2023 currently sitting at 29,2XX miles so it is still under warrently.....I wanna check to see if the crack goes all the way up to the drain plug itself because I think that will give me more information.

 

[Brian_B]

I just hope the dealer doesn’t try to say you overtightened the plug or something silly

 

[daniel.edwards2019]

That's the part I am worried about I know I didn't over tighten it but it comes down to what the dealer says.

Sponsored