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Unread 11-04-2007, 10:55 AM   #1
mud n rox
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Solid Axle Diff Cover

I'm installing a Solid Axle Diff Cover today. It has the raised fill plug on it. My question is how much fluid do I put in?? Do I go with the factory specs or does it take more? 4x4xplorer says 2 qts but thats with a Rockcrusher Cover. I'm not sure if they are the same or not. Oh yea its on a D30. I searched but couldnt find a definite answer.

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[B][FONT="Comic Sans MS"][I]2001 TJ Sport - With a little lift, some armor, four mud tires, and a few decals.

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Unread 11-04-2007, 10:59 AM   #2
Jerry Bransford
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Since your rear axle has been tilted back to raise its pinion angle to match the CV driveshaft's pinion angle requirements, fill it to the raised fill hole. Tilting it means the OE fill hole is lowered so it's hard to get enough gear lube into the housing. The raised hole of your new cover allows enough gear lube to be added without spilling out during the fill process.
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Unread 11-04-2007, 11:00 AM   #3
robncar
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For the D30, it's 2.5 pints (1.25 quarts) according to the FSM, not 2 quarts. The fill plug is higher on the Rockcrusher / Solid covers, you don't want to overfill as the lube will be pumped out the breather tube = big mess.


FRONT AXLE .03 L (1 oz.)

181 FBI (Model 30) 1.2 L (2.5 pts.)

Last edited by robncar; 11-04-2007 at 11:57 AM..
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Unread 11-04-2007, 11:00 AM   #4
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Quote:
Originally Posted by Jerry Bransford
Since your rear axle has been tilted to match the CV driveshaft's pinion angle requirements, fill it to the raised fill hole. Tilting it means the OE fill hole is lowered so it's hard to get enough gear lube into the housing. The raised hole of your new cover allows enough gear lube to be added without spilling out during the fill process.
Jerry, isn't the OP talking about the D30?
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Unread 11-04-2007, 11:44 AM   #5
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Quote:
Originally Posted by robncar
Jerry, isn't the OP talking about the D30?
Oops yep he is, thanks.

The front axle should be filled per the axle specs which is pretty close to 1.8 quarts. Overfilling it to the top of the new cover's elevated fill hole is just likely to cause gear lube to leak past the seals.
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Unread 11-04-2007, 01:14 PM   #6
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[B][FONT="Comic Sans MS"][I]2001 TJ Sport - With a little lift, some armor, four mud tires, and a few decals.

Caution: Rock and a hard place just ahead.

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Unread 11-11-2007, 10:41 AM   #7
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I noticed something. The Solid cover is deeper than the stock cover. It comes out farther from the axle than the stock cover. Would this make any difference in the amount of fluid in the diff?? I only ask this because I put in the 1.25 qts and when I drove it I got a weird kind of clicking noise that wasnt there before the cover change.
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Unread 11-11-2007, 10:44 AM   #8
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Perhaps it's interfering with the draglink/tierod, there's not much clearance in that area.
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Unread 11-11-2007, 10:49 AM   #9
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I thought of that but there's no marks on the cover or drag link/tie rods.
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[B][FONT="Comic Sans MS"][I]2001 TJ Sport - With a little lift, some armor, four mud tires, and a few decals.

Caution: Rock and a hard place just ahead.

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Unread 11-11-2007, 10:54 AM   #10
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Quote:
Originally Posted by mud n rox
I noticed something. The Solid cover is deeper than the stock cover. It comes out farther from the axle than the stock cover. Would this make any difference in the amount of fluid in the diff?? I only ask this because I put in the 1.25 qts and when I drove it I got a weird kind of clicking noise that wasnt there before the cover change.
Yeah, I noticed this when doing mine the other day. I filled it till I could feel the oil with my finger. That's what I do at work.
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Unread 11-11-2007, 12:32 PM   #11
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Quote:
Originally Posted by 04WranglerX
Yeah, I noticed this when doing mine the other day. I filled it till I could feel the oil with my finger. That's what I do at work.
Yep, usually a good plan, the ol' finger test. The RockCrusher and Solid covers have there fill plugs higher up though as compared to the stock covers. So, with the finger test, you may overfill.

I think I'd jack up the front end (both front wheels off the ground) and spin the front axle by hand and listen for your clicking sound to try to find out where it's coming from. You could also cycle the steering gear lock to lock. This would be easiest with an assistant. I've seen the Rubi guys speak on an issue with clearance if you tighten the fill plug too far (I use teflon tape on my fill plugs and make them "snug"). Make sure nothings rubbing on the new cover, inside or out.
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Unread 11-11-2007, 01:27 PM   #12
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Quote:
Originally Posted by robncar
I use teflon tape on my fill plugs
I was just wondering about doing that. The teflon tape won't cause any problems?
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Unread 11-11-2007, 02:02 PM   #13
mud n rox
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Quote:
Originally Posted by robncar

I think I'd jack up the front end (both front wheels off the ground) and spin the front axle by hand and listen for your clicking sound to try to find out where it's coming from. You could also cycle the steering gear lock to lock. This would be easiest with an assistant. I've seen the Rubi guys speak on an issue with clearance if you tighten the fill plug too far (I use teflon tape on my fill plugs and make them "snug"). Make sure nothings rubbing on the new cover, inside or out.
Thats a good idea. Will keep you posted. I guess if that doesnt work I can always put the stock cover back on and see what happens.

The new cover was installed the first of the month but the jp had to sit for a while once the problem was found (not my DD). Yesterday I pulled the new cover to inspect things. I found no foreign objects or metal shavings. No marks on the inside of the cover or the plug. The plug barely goes through and does have teflon tape on it.
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[B][FONT="Comic Sans MS"][I]2001 TJ Sport - With a little lift, some armor, four mud tires, and a few decals.

Caution: Rock and a hard place just ahead.

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