Repair leaking front diff cover

I mentioned, somewhere, that I had an oil leak from the front cover diff. My car get serviced at Mitsubishi and I got quoted $400 to have this leak fixed. My original idea was to wait as I wanted to fit a front ARB diff lock. We don't know if the ARB diff lock can be fitted but they were ready to give it a try, at  worse (no front locker available) they would have fixed the leak. Anyway, the front diff lock will be for much later and I got sick of having this leak, so I fixed it last night!!

At first, I went hunting for a new gasket, and as often, no one got one, so I went to Mitsubishi and ... they don't have one either because there isn't one! just some sealant.

It took me about 3 hours and as being a bit stubborn, sometime it is a good thing! (I didn't want to remove completely the diff) 

I have done it without completely removing the diff of the car. I disconnected the 3 mount bracket, the front drive shaft from the back of the diff (not the CV joint), removed the driver side wheel, and the engine stone protection. I removed the oil from the diff. By rotating and then lifting the diff I managed to remove all the 8 bolts that hold the cover.

In this position, the cover was away from the diff but there wasn't room to take it out completely (between the diff and the cross member), I tried for 20 min but I couldn't do it!! So I left the cover there and started to clean the old sealant on the diff. I then cleaned the cover a small section at a time by rotating it, and then the cover slid down, and I could clean it on the bench. It was good to have the cover out of the car but it took me 30 min to slide it back in! Once the cover was back in, I used some "loctite 518" and apply it on the cover, one section at the time, again by rotating it and being careful that it didn't touch the diff itself.

All bolts are back on, I just have to put some new oil. I will  keep an eye on it to make sure it is all good. (I hope it is!)

I am not sure if the "loctite 518" is the best sealant for this application but I think that it is a very good product, only time will tell!

It can be done this way, but it is probably not be the best way!! because of the lack of space, it was very "tricky" at time... but it can be done...and it save me $400.

I am not sure, but my next idea to get the cover out of the car was to disconnect the steering rack (the knuckle) as it may have enough space there??

Happy io.

Cover appart...

Cover completely removed

All back in...what a pain of a job!