Water enters my Jimny's front differential: No clue on how to fix issue

The service guys do not know how the 4WD system works or how to remedy the flashing error code.

BHPian chsai recently shared this with other enthusiasts.

Hi all,

I am in a fix; during the last 2 weeks of heavy rains in Hyderabad, my Jimny got me out through some situations of rain and slush, but it never was in deeper water than 30 cm. Post which the 4WD drive light started flashing when the car is idle but goes away when the car is moving, I immediately took it a Nexa service centre near my place, they said due to water splashes right upto intake duct this might be happening but will go away, this was on a Saturday. They were not ready to take it up, requested them to at least wash it. They were busy, so I took it back on Monday to them for wash and insisted they check all fluids, but they were reluctant, but I insisted, so they check the front and rear differentials; the rear differential oil was normal. However, the front differential oil was milky white; the SA said that was normal.

I insisted they change that and the engine oil to be on safe side, but they were not ready to and tried to convince me it is absolutely unnecessary, after persisting they just changed the engine oil which they said was unnecessary at 3100 km, I asked them to do that atleast, so they just changed the oil and oil filter, i asked them to put synthetic which they didn't have stock so put regular oil, the 4w light thing they had no clue and told me it will go away once i do a little bit of dry runs, tuesday i was busy and when i took it out wednesday morning again the light started coming, so went to them again and asked them diagnose the 4WD light issue and to change the diff oil as i thought water had entered the diff, dont know how though, they were not keen to look at it and they then directed to me another branch of theirs where they had better Techs, I was not confident of them anymore based on the experience and knowledge level, took it to another service center belonging to the group i took delivery from on the opposite side of town, they immediately checked everything and found the front diff oil to be white, i asked them to change that and the airfilter, surprisingly they dont have both and not available anywhere in hyderabad asked me to keep the vehicle at service center till these come after 4-5 days and also to investigate further, which is a surprising response from Maruti Nexa service.

My query to 4WD experts is:

1. Did the water get into the diff during these water and slush drives?
2. If so, how did it get there? Did any of you guys experience something similar after some slush or water wading?
3. Or my initial fear that something was wrong in the drive train from the day when I took delivery was that the vehicle had a very high NVH, which I mentioned in my previous posts too that NVH was too high for Japanese vehicles; it was not moving freely and was feeling strained all the time, and I got it checked by at least five tech persons at diff service centres, and they all said it might be because it's new and it will even out
4. Was it because they forgot to put oil in the differential at the factory, and the vehicle had been flushing oil throughout? And we discovered now, as you can see from the picture, that it is not having the consistency of gear oil but is more like water.
5. Is the 4wd drive light flashing at a standstill due to this, or is it a separate issue?

I appreciate your input. Thanks

Here's what BHPian Sankar had to say on the matter:

If the oil is milky white definitely water has definitely gotten into the differential, without a doubt. Change the differential oil pronto. Stock Jimny diff oil is 75w85 synthetic light golden yellow and smells good too. Don't ask how I know.

In the front axle there are two ways water could have seeped in 1) through the breather and 2) through the vacuum line. Since the 4WD logo is blinking and not lighting solid I suspect there could be a leak in the vacuum circuit. Without positive vacuum feedback light does not get solid, it should light up solid even at a standstill with the engine on once the front hubs are engaged. So get that thoroughly checked for loose/disconnected/torn vacuum tube/fitting. Water could have got in through there. A differential breather is another suspect, check if it's stuck open you can do it by hand it should move freely.

Since it's under warranty if there is any issue with the transfer case/front differential claim in and change it. With customer Jimnys being used for test drives one cannot expect random guys new to 4WD to use it properly.

Jimnys don't leave the Maruti plant without oil in the Tcase, differentials or engine, so you can rule that out.

BHPian chsai's update on the matter:

I am also genuinely shocked with the Nexa service experience; none of the Nexa service guys in any of the service centres in Hyderabad has any clue about Jimny's 4WD tech. Water entered my diff, and they have no clue how? When I asked them to change the oil, one guy said that's how the new milky white oil looks and refused to change it, I went to another they refused even to check saying that not even possible and will do it at the 10k check and asked me to drive on after I know fully well that it's contaminated. After I insisted on a change, they tell me they do not have the differential oil in stock and would take a week. They don't even have an air filter, even washing; they are clueless about how to do it properly. After a water and slush run, I went to a Nexa service, I think when they washed it from below, the water entered into the diff, also mud splashed at the intake was forced into the air filter while washing as there is no way water can enter it while wading through less than 30 cm water, now the air filter is dirty, and they don't have a replacement, the 4wd light flashes intermittently while driving and goes away on its own and none of the service tech's is unable to explain how water got into the diff, why the 4wd is flashing, why there is a random wobble that comes and goes on the tarmac at speeds? Why car is pulling to the left when braking? Why is there less oil in the transfer case? Why the car has a high NVH?

Their initial reaction is OMG you have taken it through rain and slush as the engine compartment looks dirty so water must have entered then and trying to convince me that the car got water logged and future warranty claims if any will not be applicable, i showed them the interior of the car and not a drop of water in the cabin or on the floor and that it is not water logged and insisted i get a proper explanation which they said they dont have and needs further investigation after keeping the car for two days, then i took eneos diff oil from out side and got it changed even when they were hinting that warranty will get voided if they do that, the standard reply post that is we have escalated to Maruti and awaiting their reply and after more than a week of followup, i gave up, no sign of when the airfilter or the diff oil will come, now the 4wd light flashing has reduced significantly, comes and goes randomly while driving and hope it will go away soon, i never expected this from Nexa!! Most service centres are good for routine checkups and oil changes, but for anything complex, they are not geared for it; they do not know how the 4wd system works or how to remedy the 4wd flashing error code, I wonder if Maruti has even done an orientation program on the Jimny for the mechanics? I have had other European cars for the last 20 years, and their service levels could have been better in India, but now I feel they are better in many ways, I hope to live with Jimny without ever revisiting a Nexa.

P.S: All fellow Jimnyists, a word of caution, please check all fluids after a water and slush run and wash it carefully, Jimny is not what we think it is :(

Here's what BHPian Turbanator had to say on the matter:

Most dealerships will have newer car washers ( water preservation), so the chances of water getting during the wash can be less. Remember, they are Maruti service stations, not Force motors so they will be washing most of the cars like Baleno/ Breeza.

Water depth can be deceptive, and on a moving vehicle, it can enter with a large force. So even if it's not deep, it might have gone if the car was at speed.

Look for any missing/ loose breather vent plug.

If you are 100% sure this is attributed to some manufacturing issue, escalate this to Maruti. Wait until they answer, as they will also like to understand this, and it's essential to keep things preserved for a Root cause analysis. However, if you feel this can be attributed to driving in water, you can change the Differential oil immediately. In either case, don't drive the car.

Try another test drive car. It might be similar in other vehicles too. If not, it will be tricky to find the reason. Alignment issues can be ignored probably if your car usually drives straight and goes on the left only under braking. On an old vehicle, there can be some issues of wear and tear of suspension/ rotors but on a new car? So, I will start with driving another test drive car first.

Here's what BHPian Jaggu had to say on the matter:

This is a serious issue, even if the whole car was submerged for a few minutes water should not enter the diff like this to make it white. I had seen earlier posts by others that pointed to water entry and that you were attending to it so did not bother much.

But if Nexa guys don't even understand water contamination in oil and how it can ruin bearings including diff, they should not be worthy of any workshop!

Get the details of the regional manager and escalate, also send a strong email with images to Maruti.

Check for Ignis height adjust unit, should be almost a direct fit to Jimny.

Check out BHPian comments for more insights and information.