I have an after market rear diff. cover, so I am not really sure where the bottom of the OEM fill hole is, which dictates the gear oil level in the diff., and the axle tubes.

After fixing a small, weeping leak from a threaded hole in the cover, I would like to fill to the correct level.

Question: Where is the bottom of the OEM fill hole in relation to the bottom of the axle tubes?

Thanks in advance.

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06 CRD LIMITED- Factory Belly Armor, Hooks.
EHM, MagnaFlow SS Cat Back, FS-2500, HDS 001 TStat, Some Gauges, PML Trans Pan, PML Diff Cover, Marinco Mod, FIA Blanket, Cooper Discoverer ATR 225/75, CTS 245/70, Front-JBA 2.25" C/Os, Rear-OME HD, JBA UCA, SS Brake Lines.

I would rather just drain the gear oil completely and fill with 4.4 pints = 2.2 quarts of fresh gear oil in the read differential. I just did the exact same thing when I installed after market aluminum differential cover with a drain plug on mine a week ago.

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'06 Liberty CRD Limited. Bought at 91K miles.
ARP studs, New rockers, Stant inline tstat, Weeks 1&2, Provent, IDParts Silicone hoses,
2-1/2" Full OME lift, Timing belt, Water pump, TransGo kit, Plastic fan, Fumoto
2nd gen fuel head with 2nd stage 2 micron filter, in-tank lift pump, G2 Rear Diff Cover

This strategy only works if the new cover has the same volume as the OE one and doesn't change the capacity of the axle.

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Share your ideas freely at https://www.facebook.com/groups/libertydiesels/

You are correct. How did I miss that? Time to measure the fill hole on the old cover. BTW I still have the old cover so I will report back soon.

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'06 Liberty CRD Limited. Bought at 91K miles.
ARP studs, New rockers, Stant inline tstat, Weeks 1&2, Provent, IDParts Silicone hoses,
2-1/2" Full OME lift, Timing belt, Water pump, TransGo kit, Plastic fan, Fumoto
2nd gen fuel head with 2nd stage 2 micron filter, in-tank lift pump, G2 Rear Diff Cover

This is the exact reason I bought the PML diff cover even though it cost about $40 more than the Nitro cover and about $50 more than the G2 cover. It has a side fill hole at the same height as the OEM cover fill hole. I like the easy "fill it till it runs out the hole" method. With the PML cover, the rear axles requires an additional .75 quarts of gear oil.

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2006 CRD Sport
GDE FT ECO tune, GDE TCM ECO tune, ARP studs, HDS-001 203F T-Stat, 3.7L nylon fan & Hayden 2905 clutch, Carter P76148M in-tank pump, Racor 245R122 filter head & 2 micron R25S fuel filter, Provent 200, Samcos, Fumoto F-102, Litens 920834A de-coupler, PML rear diff cover, OEM trans pan with welded in bung, JBA UCAs, full skids.

@pjigar, thanks for offering to take that measurement off the OEM cover, and please, if possible, report back real soon for both our sake.

Much appreciated.

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06 CRD LIMITED- Factory Belly Armor, Hooks.
EHM, MagnaFlow SS Cat Back, FS-2500, HDS 001 TStat, Some Gauges, PML Trans Pan, PML Diff Cover, Marinco Mod, FIA Blanket, Cooper Discoverer ATR 225/75, CTS 245/70, Front-JBA 2.25" C/Os, Rear-OME HD, JBA UCA, SS Brake Lines.

@95Z28A4, could you also please take a measurement from the bottom of the fill hole to the bottom of the axle tubes?

Thanks in advance.

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06 CRD LIMITED- Factory Belly Armor, Hooks.
EHM, MagnaFlow SS Cat Back, FS-2500, HDS 001 TStat, Some Gauges, PML Trans Pan, PML Diff Cover, Marinco Mod, FIA Blanket, Cooper Discoverer ATR 225/75, CTS 245/70, Front-JBA 2.25" C/Os, Rear-OME HD, JBA UCA, SS Brake Lines.

Factory differential cover: Bottom of the diff cover cavity to bottom of the fill hole = 7 inches

My G2 cover has a fill hole at about 6 inches. I tried filling my differential up to the G2 fill hole and it took close to 7 quarts! I questioned that how can it take 7 quarts in a differential cover? I drained about a quart and oil level was 0.5 below the fill hole. So I was not overfilling. But I still can't believe that I have 6 quart of gear oil in the rear differential. Am I doing something wrong?

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'06 Liberty CRD Limited. Bought at 91K miles.
ARP studs, New rockers, Stant inline tstat, Weeks 1&2, Provent, IDParts Silicone hoses,
2-1/2" Full OME lift, Timing belt, Water pump, TransGo kit, Plastic fan, Fumoto
2nd gen fuel head with 2nd stage 2 micron filter, in-tank lift pump, G2 Rear Diff Cover

No, you are not doing something wrong. The cover is made to hold extra oil capacity, but supposedly at the same "level".

Check out the large "buldge" in the cover vs. the OEM cover.

But the 7" vs. the 6" to the bottom of the fill hole, if you "fill till it runs" is what I want to find out and would question.

Thanks for the measurement of 7" on the OEM cover.

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06 CRD LIMITED- Factory Belly Armor, Hooks.
EHM, MagnaFlow SS Cat Back, FS-2500, HDS 001 TStat, Some Gauges, PML Trans Pan, PML Diff Cover, Marinco Mod, FIA Blanket, Cooper Discoverer ATR 225/75, CTS 245/70, Front-JBA 2.25" C/Os, Rear-OME HD, JBA UCA, SS Brake Lines.

I was so concerned and confused so I called G2 technical support. The G2 rear differential part number is 40-2029ALB. According to G2 technical support: G2 40-2029ALB rear differential cover takes factory recommended gear oil fill. They also said that their fill hole is set "higher" than factory! That got me thinking so I went back to OEM cover and put it side by side with G2 cover. I realized that I measured the OEM cover fill hole incorrectly. The OEM fill hole bottom is 3-3/8" from the bottom of OEM cover cavity. I am so sorry about measuring the OEM cover fill hole height in incorrect direction before, I had the cover turned 90 degrees.

So in summary: G2 cover has fill hole set way higher at about 5-1/2" compared to OEM fill hole at about 3-3/8". The correct fill amount for G2 cover is 4.4 pints (factory) or 2.2 quarts.

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'06 Liberty CRD Limited. Bought at 91K miles.
ARP studs, New rockers, Stant inline tstat, Weeks 1&2, Provent, IDParts Silicone hoses,
2-1/2" Full OME lift, Timing belt, Water pump, TransGo kit, Plastic fan, Fumoto
2nd gen fuel head with 2nd stage 2 micron filter, in-tank lift pump, G2 Rear Diff Cover

They do that since in most cases your putting a aftermarket HD cover on after lifting which will tilt the rear diff requiring the fill hole to be raised otherwise you will not be able to get the correct amount of oil in the rear diff.

Try filling my rear diff,Curries RockJock60 with the diff cover at a 60 degree slant the complete opposite way.