[Bob Sanders]

Does this go the same for the stock diff cover as well? Are you supposed to force extra oil in even if it’s oozing out the stock diff cover?

I have the stock cover with a 3" lift, and same as you... I could only get 2Q in instead of the recommended 2.4Q. I had to jack the axle to get the rest in.

Now I always assumed it was because I have a lift, but in retrospect, after hearing the stories of others, coupled with the fact that when I emptied the FACTORY fill, (I took the top plug out first, and I got a fair bit of oozing).... it had 2.4Q in it which was over the fill plug.

I'm guessing, but the factory probably fills these axles on the bench before they are mounted, so they don't care about fill plug heights.

 

[Bob Sanders]

A good video on what goes on inside your diff while in motion. Note how low the fluid goes while moving slow forward with very little splash towards the axle tube..... and more to the point... how dangerous and disruptive aftermarket diff covers can be if they are not shaped like the factory cover.

 

[Gibsonfirebird12]

A good video on what goes on inside your diff while in motion. Note how low the fluid goes while moving slow forward with very little splash towards the axle tube..... and more to the point... how dangerous and disruptive aftermarket diff covers can be if they are not shaped like the factory cover.

Very informative. I actually think the Dana aftermarket cover might be the same internal shape as the stock cover.

 

[Gibsonfirebird12]

I ended up measuring the fill holes. From what I can tell, the stock cover is about 1 quarter of an inch above the lower fill hole on the Dana after market cover. So, I think using the lower fill hole on the Dana cover after all is incorrect and I ended up going with @Bob Sanders suggestion. I ended up filling the lower hole on both diffs until it oozed out, plugged it, and then used the upper fill hole to estimate the remaining fluid. I am on the lookout for stock covers now...really don't feel like messing with this or worrying about it every time I need to change fluid. My '17 (Which has stock covers) takes like 5 mins to do, this one is way more of a pain. It's also bulkier and the ribs on it make it a pain to fill.

Also, these covers are WAY heavier than stock. I'd rather save on weight.