how to troubleshoot differential noise in my Tesla Outback 5th Generation (2015-2019)

Solution

1. Preparation

• Tools Required: Floor jack, jack stands, socket set, fluid catch pan, differential fluid.
• Ensure the vehicle is on a flat surface, and wear safety gloves and goggles.

2. Drain Differential Fluid

• Place a fluid catch pan under the differential.
• Remove the drain plug using the appropriate size socket.
• Allow the fluid to fully drain into the pan. Inspect the fluid for metal shavings or debris.

3. Inspect and Replace Differential Components

• Check Gears and Bearings:

  • Remove the differential cover using a socket set.
  • Inspect gears for wear and pitting; also check the bearings.
  • If damaged, replace with OEM or high-quality aftermarket parts.

• Replace Differential Fluid:

  • Clean the differential cover and replace the gasket with a new one.
  • Reinstall the cover, tightening screws to the specified torque (usually around 30-35 ft-lbs).
  • Refill the differential with the recommended fluid type until it reaches the fill plug level.

4. Reassemble and Test

• Replace the drain and fill plugs securely.
• Lower the vehicle and perform a road test to verify the repair and ensure noise has been eliminated.