Originally Posted By: ledslinger
2003 Chevy Silverado 4 X 4 1500, front diff. Out Castrol Syntec, in Royal Purple 75w90. I changed the factory fill at about 25K miles and was a little concerned at how the fluid looked. There was a gob of moist looking fluid that came out first when I pulled the drain plug. Probably because the front diff has never been warmed up since I bought the truck new. I only use 4 WD for short runs up a grassy hill or when pulling a boat up a ramp. About the only time I could foresee warming up the diff is in snow, but I've never driven the truck in snow.
So when I did the change at 25K I found out about needing to change the threaded vent adapter if running synth. Since I didn't like the looks of the factory fill I decided to change the fluid when I changed the vent adapter, which turned out to be at 3K miles on the odometer. This is probably a few miles on the the front diff at most. I would be surprised if the front diff has run over 5 miles in the 28K miles on the truck.
There was another bit of goo near the drain plug, this time black instead of moist looking. I think the diff has some residue and the oil gets a bit stagnant from non use. I'm not going to run it on dry roads long enough to get it warm since thats not good on the drivetrain, and I rarely drive it on wet, snowy or gravel roads.
I thought it strange GM would make you buy a fitting that is white to replace a black one just to get an O ring that will tolerate synth. Looking at the fitting, they changed the rotating vent baffle to metal from plastic, probably to make it more reliable at being in the correct orientation. The original O ring was black with an orange coating, and was deteriorating, not necessarily due to synth oil though. It was more deteriorated where it was exposed to air.
So it appears the incentive to replace the fitting is more than just due to intolerance to synth oils, but a poor deteriorating rubber compound, and an improved and more reliable rotating baffle.
Since I've owned this truck for 11 years, I'm late to the party when it comes to my understanding of how this front diff works. I didn't know what shafts turned during 2WD. Now I understand that the CV half shafts, and left stub axle turn with the wheels. The actuator motor works a fork and splined dog that disconnects the right half shaft from a short intermediate shaft. The ring, pinion and driveshaft don't turn, but I don't know if that is due simply to friction, or if something in the transfer case restricts them in 2WD. Since the ring gear and carrier is stationary and the left stub is turning, the side or spider gears are turned, which rotates the right intermediate axle backwards. When the 4WD is actuated the driveshaft and ring gear go quickly to road speed and I assume there is a short delay until the right imtermediate axle goes from spinning backwards to road speed, so the splined cog can engage the right flange stub.