bent my differential cover -- plus fix

That is one hell of a fix!!!

Nice!

Cal,
Nice pictorial on the 'fix'. I've been through this time and again with my solid axle rock crawlers. The only part that needs upgrading is the very bottom of the cover. This is the part that drags on the rocks, especially with that big AAM axle hanging down. I suggest grinding off about 1/8 of an inch along the bottom of the cover so it's not the first thing to drag. I've tried thicker covers, and the best solution for me was a cover with a built in cage along the lower half. Of course, most of the time for you, you'll be moving forward before the hit, so a cage is not necessary. The other winner was something called, "The good stuff", a space age goo for your cover plate. Very flexible.
jefe

That fill plug looks way too high up. You will be over filling the rear end,which will cause axle seal leaks.
Just my $0.02

It sure looks strong, but with vehicles everything boils to proper balance of several factors for optimal performance.
If that cover in fact is build with 3/8" plate, that adds 20-30 lb of weight.
One case of beer you have to leave at home and not take with you camping.

Home Skillet wrote:
That fill plug looks way too high up. You will be over filling the rear end,which will cause axle seal leaks.
Just my $0.02

Very true, the bottom of the fill plug should be slightly above bottom of the inside of axle tube. As stated above, seal failure is emminent.

It needs paint.

Yep, it's wrong. Probably had the metal upside down when he formed it.
Fill hole should have been as much below the C/L as it is above.

Home Skillet wrote:
That fill plug looks way too high up. You will be over filling the rear end,which will cause axle seal leaks.
Just my $0.02

Spent some time on this question - so yes, I was aware of the issue and thought about it. And DID NOT fill to the fill hole, which is 3/4" higher than stock. The correct level is as stated here: 'The correct oil level should be between the bottom of the inside of the axle tube and bottom of the axle shaft.'

I measured to the bottom of the axle tubes on both sides, and also used a good level to locate the (outside) bottom of the tubes on the differential cover. Added 1/4" for the tube thickness, and added 1/4" above that -- which is still well below the axle shafts.
That procedure defines the max fill level, in my well-informed opinion.
In the second to last picture, one may notice an 'etched' mark on the cover (made by me with hammer and chisel). That is the max fill line.

I admit it was a little 'tricky' determining when the oil level was at max -- but it is. Takes 4.5 quarts Amsoil 75-90, minus the small amount left in the bottles and the funnel.

trail-explorer wrote:
It needs paint.

--- several clear coats. --- I like how it looks without paint.