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Discussion Starter · #1 ·
Decided to add a SOLID brand diff covers during my first diff oil change. That SOLID cover is built like a tank and should protect the gears a lot better than the OEM sheet metal cover. Once I got it on, I started wondering if it would interfere with the rear AEV track bar at full articulation. (AEV 2.5" DualSport lift) I'm going out this weekend to try to flex the system to see if I can get a better idea, but maybe someone has already gone down this path and can offer some advice.
As it stands, there seems to be plenty of clearance for most travel and a certain amount of axle travel but I don't want to hear clunks when I really put a twist in the suspension.
Anybody?
 

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Decided to add a SOLID brand diff covers during my first diff oil change. That SOLID cover is built like a tank and should protect the gears a lot better than the OEM sheet metal cover. Once I got it on, I started wondering if it would interfere with the rear AEV track bar at full articulation. (AEV 2.5" DualSport lift) I'm going out this weekend to try to flex the system to see if I can get a better idea, but maybe someone has already gone down this path and can offer some advice.
As it stands, there seems to be plenty of clearance for most travel and a certain amount of axle travel but I don't want to hear clunks when I really put a twist in the suspension.
Anybody?
Installing my cover this weekend. Have you had any problems with contact? I still have a stock trackbar and it looks like there is enough clearance. Hopefully no issue. How much gear lube did you use? Just fill to the hole? Looks at about stock height.
 

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Discussion Starter · #3 ·
Installing my cover this weekend. Have you had any problems with contact? I still have a stock trackbar and it looks like there is enough clearance. Hopefully no issue. How much gear lube did you use? Just fill to the hole? Looks at about stock height.
Finally put the SOLID covers on both diffs and have had to interference yet at either end. I installed a steering stabilizer relocation kit to move the cylinder above the tie rod and found a clearance problem with the stabilizer bracket when turned full driver side. A little tweak with the SawZall and problem went away.
The SOLID diff covers have the fill hole quite a bit higher than the stock cover. Before I removed the stock cover, I marked the fill height on the axle so I could get it close to the proper fill level. Turns out that it's about the height of the lower inner dia. of the axle tube. If you fill to the SOLID fill level you're going to be putting in WAY too much oil. I made a dipstick out of a piece of wire and got it close to stock level.
 

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Great! Thanks for the advice. I am thinking about 2.5 quarts in the rear and see where that lines up with the mark of the original fill hole.
 
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