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Old 05-10-2014, 09:30 PM   #1
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Possible to overfill diff covers?

I have an 08 Rubicon and was upgrading the diff covers to the "Solid Axle Industries" covers this afternoon. I bought 4 quarts of amsoil with the expectation that the front will take 1.3Qts and the rear will take 2.7Qts. I only got the rear completed before it got dark, but it took a full 3Qts without anything coming back out of the fill hole, I checked for leaks but there were not any. I looked on SOLID's website and it doesn't appear to say anything about giving extra room for additional fluid, so I was just wondering if this was going to cause any kind of problem?

I haven't done the front yet, because now I don't have enough fluid, but I feel like it's more than likely going to take a full 2Qts instead of the 1.3Qts like originally stated.

What do you guys think?

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Old 05-10-2014, 09:39 PM   #2
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Put just the factory spec amount of fluid in there. The rear should be just over 2 quarts and the fronts just over 1. Aftermarket diff covers will normally have a higher fill hole this getting rid of using it as a guide.

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Old 05-10-2014, 09:45 PM   #3
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Would it be wise to drain some of the fluid back out of it?
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Old 05-10-2014, 09:51 PM   #4
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Yes. Otherwise itll puke out of the breather hose and other places and make a nasty mess.
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Old 05-10-2014, 09:54 PM   #5
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Awesome, will do! Thank you sir.
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Old 05-10-2014, 09:58 PM   #6
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Originally Posted by tab22092 View Post
Yes. Otherwise itll puke out of the breather hose and other places and make a nasty mess.
^^^This. My front Dana 44 was overfilled from the factory when new. And it pushed oil out the breather, and dripped all the way down onto my lower driver side CA, and then onto the floor. I had to drain it out to the correct fill level, and then wash everything with Brake Clean.
So don't overfill it........
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Old 05-10-2014, 10:18 PM   #7
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Dana 44 is 2.375 qt ( 4.75 pints)
Dana 30 is 1.3 qt ( 2.75 pints)
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Old 05-10-2014, 11:09 PM   #8
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Dana 44 is 2.375 qt ( 4.75 pints) Dana 30 is 1.3 qt ( 2.75 pints)
Definitely got pints and quarts mixed up, thanks for clarifying. I only drained 8Oz out, leaving 2 Qts and 22Oz remaining. Will get more out tomorrow!
Really appreciate you guys warning me, I had oil messes.
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Old 05-11-2014, 05:55 AM   #9
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I would be concerned that using the factory amount in a higher capacity cover wouldn't allow the required oil depth. Isn't the whole point of a larger cover higher oil capacity, meaning cooler oil?

If its overfilled, it could spooge out the breather, underfilled is a way worse scenario. I'd find out for sure before I drove it!
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Old 05-11-2014, 06:54 AM   #10
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I would be concerned that using the factory amount in a higher capacity cover wouldn't allow the required oil depth. Isn't the whole point of a larger cover higher oil capacity, meaning cooler oil?

If its overfilled, it could spooge out the breather, underfilled is a way worse scenario. I'd find out for sure before I drove it!
Correct. That is the point of an aftermarket dif. cover, increased capacity. If the "factory" overfills the oem dif. then there will be a problem. Increased fluid equals increased volume and pressure because the "factory" can fill above the fill hole and it will push out of the point of least resistance whether that's the vent, seals, or both. Aftermarket fill cover holes are engineered for the actual fill, so you basically can't overfill. The purpose is "increased" capacity so filling it to the bottom of the fill hole until it weeps out which you would normally do is where the level should be. Lubelocker gaskets with the dif. cover would work out nice too.
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Old 05-11-2014, 06:59 AM   #11
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I replaced my covers yesterday. If anything I should not have to change my fluids every 15k miles? But shouldn't have to keep removing the diff covers right?
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Old 05-11-2014, 07:22 AM   #12
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I replaced my covers yesterday. If anything I should not have to change my fluids every 15k miles? But shouldn't have to keep removing the diff covers right?
You should have a drain plug on the bottom of your diff's takes 3/8 ratchet to take out . Mine does
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Old 05-11-2014, 07:22 AM   #13
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Correct. That is the point of an aftermarket dif. cover, increased capacity. If the "factory" overfills the oem dif. then there will be a problem. Increased fluid equals increased volume and pressure because the "factory" can fill above the fill hole and it will push out of the point of least resistance whether that's the vent, seals, or both. Aftermarket fill cover holes are engineered for the actual fill, so you basically can't overfill. The purpose is "increased" capacity so filling it to the bottom of the fill hole until it weeps out which you would normally do is where the level should be. Lubelocker gaskets with the dif. cover would work out nice too.
Wrong. Call poison spyder and ask them the correct amount of diff fluid to use for their bombshell diff covers. They will tell you factory spec. How do i know? Because i have them. And secondly because i witnessed first hand what happens when they are overfilled as the guy who did my gears went all the way to the fill hole.
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Old 05-11-2014, 07:34 AM   #14
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No matter what aftermarket diff cover you have,you should set them side by side and mark were fill level would be on stock cover in reference to new cover.On level ground oil level should be just a little higher than the bottom of the axle tube.
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Old 05-11-2014, 07:50 AM   #15
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Originally Posted by tab22092 View Post
Wrong. Call poison spyder and ask them the correct amount of diff fluid to use for their bombshell diff covers. They will tell you factory spec. How do i know? Because i have them. And secondly because i witnessed first hand what happens when they are overfilled as the guy who did my gears went all the way to the fill hole.
X2
Fill to factory spec. The poison spyder has thicker walls but doesn't provide a larger cavity
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Old 05-11-2014, 08:06 AM   #16
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You should have a drain plug on the bottom of your diff's takes 3/8 ratchet to take out . Mine does
Yeah it does. What am saying is there should be no need to remove the diff unless you have a possible leak correct?
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Old 05-11-2014, 08:14 AM   #17
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Yeah it does. What am saying is there should be no need to remove the diff unless you have a possible leak correct?
Yes correct..for general maintenance no need to remove cover.
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Old 05-11-2014, 08:21 AM   #18
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Originally Posted by _3m View Post
X2
Fill to factory spec. The poison spyder has thicker walls but doesn't provide a larger cavity
X3-

I have the PS Diff covers as well, but looked at a variety of others. All of the directions said to mark it on the outside lined up with the factory hole and use factory specs..
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Old 05-11-2014, 08:40 AM   #19
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Originally Posted by tab22092 View Post
Wrong. Call poison spyder and ask them the correct amount of diff fluid to use for their bombshell diff covers. They will tell you factory spec. How do i know? Because i have them. And secondly because i witnessed first hand what happens when they are overfilled as the guy who did my gears went all the way to the fill hole.
Not totally wrong. Maybe for poison spyder but not all. For example:Rancho Part RS6209 - Dana 44 Cast Iron Cover Red - - 4 Wheel Parts

It's obviously best to check with the manufacturer for the brand you use to make sure there is extra capacity.
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Old 05-11-2014, 08:48 AM   #20
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Well, I did some additional digging and found this doc with fills levels for each Soild, like PS, tells you to use just above factory spec, 2.38Qts for rear 1.5Qts for front. See my original thinking too was that if they allowed for additional fluid, but I didn't put enough that it would cause larger problems then it overflowing. So, I am glad I found the chart. Really appreciate it, as always WF comes through for fellow Jeepers!
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Old 05-11-2014, 10:07 AM   #21
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That's good info. I guess the most correct answer is that it depends on the manufacturer. Here's another that holds extra capacity. Mag-Hytec Part DANA #44 - Dana 44 High Capacity Differential Cover

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