93 Ranger front differential leak RTV

[dean93ranger]

I rebuilt my Dana 35 several years ago. The front has not held fluid since; following the specified reassembly proceedures using RTV. There could be a slightly stripped bolt hole contributing to the leak. I am considering drilling thru the housing in one to three bolt holes, then using nuts and bolts to pull the housing tight to the radius arm to stop the leak. I know it's not a manufacturer approved proceedure. I just want to use 4x4 in the waning life of the truck without pulling off the front end and redoing the RTV sealing proceedure. Could it work? Are there dangers involved?

 

[fatboydan]

I'd say it could work, but your mileage may vary (pardon the pun). I say this only because on older BIG garden and yard tractors in my shop I've seen plenty of Dana 23 based differential housings that were bolt-through like that from factory. They didn't seem to leak at all if sealed (ie gaskets not rotted out, improper RTV application etc) and held well. I believe in your case, as long as you are dead careful it'll work on that too. Seems to be plenty of 'meat' to work with.

 

[RangerX]

How bad does it leak? A drip or a stream? My front diff has had a bad seal and corresponding leak for twelve years now. I can and do still use 4wd...

 

[Roadrunner777]

If you have the clearance to drill through, perhaps you have the clearance to set helicoils to restore the threads.