Just got the 4x4 TA back from a 26,000 mile "small" service at Vospers in Exeter. All filters changed, including a/c, plus oil change. 160 quid so not too horrendous. However, they've noticed that the gasket on the rear diff cover is weeping slightly - not where the prop shaft or drive shafts require a seal but just the cover on the rear of the diff casing - so I need to book it in for a warranty fix. Apparently they've seen this on several 4x4s so it would be an idea to make sure this is OK on yours before it comes up to the end of warranty.

Hi

My 4x4 Twin Air had a failed diff repair and then two new diffs (would have been expensive out of warranty!). I bought a new Panda Cross Twin Air and that has had to have a new diff as well. The service manager thought that there may have been a problem with the original diff, as the latest ones have a different reorder number. As above I would check for any leaks while still under warranty.

Mine too (63 reg MJ) has had the rear diff replaced under warranty owing to a leak. because no separate parts are listed by Fiat, the whole unit was replaced - would have been over £2000 apparently! (as mentioned in this previous post https://www.fiatforum.com/panda-iii/357283-expensive-warranty-fix-fiat-my-4x4.html)

Ay caramba! That's one non-routine check I'm going to be making on a routine basis. Let's hope they've now sorted the problem with a revised part.

Herts Hillhopper said:

Mine too (63 reg MJ) has had the rear diff replaced under warranty owing to a leak. because no separate parts are listed by Fiat, the whole unit was replaced - would have been over £2000 apparently! (as mentioned in this previous post https://www.fiatforum.com/panda-iii/357283-expensive-warranty-fix-fiat-my-4x4.html)

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They said at Vospers that it would be a simple gasket replacement, and they've already done some, so presumably Fiat have decided that replacing 50 pence-worth of seal makes more sense than a complete diff change. I'm going to book it in ASAP so we'll see.

Have just bought a two year old panda 4x4 and local garage discovered rear diff leak. Hartwell Abingdon say it will need complete replacement, > £1000 if not under warranty. Am waiting for fiat to transfer warranty. Any ideas on why this fault is happening?

Might have something to do with previous owners unnecessarily using the ELD, or it could be from bad MOT technicians putting it on rear brake test rollers, or similarly it could have been towed incorrectly. It could also be that the aforementioned 50p gasket is just that, a cheap 50p gasket.

west71 said:

Have just bought a two year old panda 4x4 and local garage discovered rear diff leak. Hartwell Abingdon say it will need complete replacement, > £1000 if not under warranty. Am waiting for fiat to transfer warranty. Any ideas on why this fault is happening?

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Apparently there are some rear diffs with sealing on the rear cover (rather than through a bearing oil seal etc)- when it was in for a service the dealer spotted that mine had a very minor leak from that source and it was replaced under warranty - took a few hours but most of that was letting the sealant semi-set prior to putting the rear cover back on.

Should have written "faulty sealing" on the rear cover.

Thanks for replies. MOT not yet an issue as is only 2 years old. Hartwell say Fiat engineer will have to confirm replacement so we'll see what he says.

I recently bought a 3 year old Panda Cross TwinAir. After a few months I noticed a small oil leak from the rear differential box. The box is in two halves bolted together and the oil was seeping from the lower part of the joint. No problem I thought, the 12 months extended warranty should sort that out. Silly me! The warranty insurance people said that it was not broken so would not fund repairs. Perhaps not surprising when I found that the cost of such a repair would be £2,000! I contacted Fiat in Italy who offered to supply a new gear box assembly for about half that but still a lot to pay for fixing a 1 drop per day leak. I found that there is a 2-part acrylic adhesive used for bonding metals, even those with slightly oily surfaces, so have given it a try (3M DP8407NS). I cut a strip of aluminum mesh to fit along the bottom edge of the differential box, i.e. over the leaking joint. Then, after thoroughly cleaning the surrounding metal with acetone, bonded the strip in place with plenty of adhesive - see picture. That was 3 weeks ago and no oil has appeared yet so fingers crossed!