bent my differential cover -- plus fix

[cewillis]

Bigger images are here.


Bent the bottom of the differential flange. Without a rock guard, it was bound to happen eventually on some of the 'roads' I drive. Very minor leak though.


Old vs new


Looks like tank armor


Old: ~1/16", new: 3/8" steel




Test fit


After some cleaning, and several clear coats.
MUCH stronger, 3/8" steel body and flange, 5mm longer grade 8 bolts, increased bolt torque from 30 to 40 ft-lb.
But I still need a rock guard -- working on it.


Alien view

[Ozlander]

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.

[trail-explorer]

It needs paint.

[eHoefler]

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.

[Kayteg1]

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]

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

[jefe_4x4]

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

[Lwiddis]

Nice!

[notsobigjoe]

That is one hell of a fix!!!