Signs of Differential Failure

Early warning signs that your diff needs attention

Differential problems often start quietly. A faint whine at highway speed or a small oil leak can be the first clue that bearings or gears are wearing. Catching the signs early can be the difference between a simple repair and a major rebuild or replacement.

Below are the most common signs of differential failure, what they usually indicate, and what you should do next. If you’re in Perth and want a professional diagnosis, call WA Diffs on +61 8 9417 9930.

WA Diff workshop
diff oil drain

Whining or howling noise

A whine that changes with speed is one of the classic diff symptoms. If it’s louder on acceleration, it can point to gear contact pattern issues or pinion bearing wear. If it’s louder on deceleration/coast, the pattern may be on the coast side of the gear teeth.

A whine doesn’t automatically mean “replace the whole diff”, but it does mean you should check oil level and condition as soon as possible.

Clunking on take-off or gear changes

A clunk when moving off, shifting between reverse and drive, or changing gears can be driveline lash. Sometimes it’s within the diff (excessive backlash, worn spider gears), but it can also be tailshaft joints or mounts.

If the clunk is getting worse or is paired with vibration, book an inspection.

toyota FJ cruiser at a workshop

Vibration under load

Vibration can be caused by many components, but internal diff issues (worn bearings, damaged gears) can contribute – especially if the vibration changes when you apply or lift off the throttle.

Because vibration is often misdiagnosed, a structured inspection is the best way to avoid replacing the wrong parts.

Oil leaks or low oil

Oil leaks at pinion seals or axle seals are common. The problem is not just the mess – it’s the oil loss over time. Low oil leads to overheating, bearing failure and gear damage.

If you can see oil around the diff housing, book it in early. A seal repair is far cheaper than replacing gears.

diff oil drain

Metal in oil

When diff oil is drained, a small amount of fine metallic paste on a magnetic plug can be normal. Larger flakes, chunks, or a heavy glittery appearance is not. It suggests active wear that needs attention.

If you’ve found metal in your diff oil, avoid heavy driving and organise an inspection.

What to do next

If you’re experiencing any of the signs above, the safest next step is a differential inspection and oil check. Call WA Diffs on +61 8 9417 9930 and describe your symptoms, when they occur, and whether the vehicle has been modified or used for towing/off-road.

If the noise suddenly becomes loud, you notice harsh vibration, or the diff has run low on oil, stop driving and get it checked to prevent further damage.

4x4 raised on hoist