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Old 03-29-2016, 12:03 AM
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dana 35 gear oil amount?

I just replaced my Dana 35 axle shaft and bought a new Solid differential cover. Now how much fluid do you put into it. I put in exactly recommend amount of 1.75 quarts. That amount barely fill up the bigger cover. Some recommend adding till fluid comes out of the filling hole. I just can't imagine added that much fluid. Has anyone who have bigger covers like Solid differential have the same problems? And how much gear oil did you fill?

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Old 03-29-2016, 12:08 AM   #2
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Yep fill it until it starts overflowing the fill hole. That is how the correct level gets set so the ring gear can pick it up and sling it around properly.

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Old 03-29-2016, 12:45 AM
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Jerry the fill hole on this cover is higher than most cover. This is the reason I bought this because after doing SYE my pinion angle changed and my rear differential angle is sitting downward so it is difficult to add any fluid into factory cover hole that is in the middle of the cover. Anything you put into the factory cover will run-out before it gets filled. This new cover has the filler hole higher so fluid will not leak out. If I add till the fluid comes out of the fill hole, I will be using like 3 quarts of fluid. I just don't want to add too much and blow any seals.
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Old 03-29-2016, 01:06 AM   #4
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The higher fill hole is positioned higher specifically to compensate for the axle having been rotated downward on the rear so as to raise the pinion angle to work properly with the aftermarket cv driveshaft installed with the SYE.
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Old 03-29-2016, 01:58 AM   #5
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I wouldn't think there is anyway you should just fill it to the plug with that diff cover.
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Old 03-29-2016, 10:39 AM   #6
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I have Nitro diff covers. After regearing, the diffs were filled to the bottom of the fill hole. The front diff slung gear oil out until it found its "preferred level." It was messy but worked,although Schafer's gear oil is a bit pricey to be doing that too often. The rear diff was fine. With aftermarket diff covers, I'm not sure if just adding the amount stated in the FSM will provide enough lubrication. Maybe this is one time too much is better than not enough.
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Old 03-29-2016, 02:12 PM   #7
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I had the same exact issue with my jeep when I upgraded covers. I held the original cover up to the new (Solid) cover, marked the location of the original fill level, filled to approximately that level and added about 1/2 quart more. It still was way below the new fill plug. It ran fine, but I added another 1/2 quart (still not near the fill port) and on my next trip to work it proceeded to spit out gear oil from the vent tube. After that 'self leveling' session all has been well with no issues. Just my .02
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Old 03-29-2016, 02:23 PM
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Just comparing the size to the factory cover I believe Solid cover will exactly hold same oil capacity. Only difference is that the fill hole is higher. It makes easier to fill. I don't think solid cover was made to hold anymore oil then factory cover. If I fill it over to the fill hole it will probably hold 4 quarts or more. I just e-mailed solid manufacturer and just waiting for their reply.
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Old 03-31-2016, 02:32 PM
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Just as info for others with solid differential or old style rock crusher cover. I just talked to the company and they suggested only put in factory recommended fluid amount. So don't add till oil comes out from filler hole.
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Old 03-31-2016, 03:04 PM   #10
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I suspect your cover has more oil capacity than stock which means if you only fill it to the precise amount spec'd by the factory, the pumpkin will be underfilled slightly. The rear axle's outer axle bearings are lubricated by gear lube that flows out of the case and down the axle tubes to the bearings. The oil level needs to be high enough that it can easily slosh out of the pumpkin and down the axle tubes to the outer bearings.

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