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Old 06-06-2021, 02:10 PM #1
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Fluid level after installing Barnes rear axle cover...

I just replaced the leaking rear axle cover with a Barnes weld on unit. The fill hole is not in the stock location, it's sitting way above. Is it considered full when the oil is sitting just below the bottom of the rear axle tube?
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Old 06-06-2021, 02:42 PM #2
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What does Barnes say?
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Old 06-09-2021, 09:20 AM #3
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They didn't say much. If i flipped the cover 180 before welding the fill hole would have been below the factory location so I opted for higher.
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Old 06-09-2021, 09:26 AM #4
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I would mark the new cover where the stock fill hole would be then just use a makeshift dipstick with something. I usually use a zip tie just put a 90 degree bend in it.
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Old 06-10-2021, 04:21 PM #5
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My buddy welded mine on for me and is a very knowledgeable mechanic. He thinks it takes a litre of gear oil, so that's what we put in it. Seems to be working well with no metal flakes. It sure is a pain to fill up though! Talk about a bad design. The track bar is now in the way.
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Old 06-10-2021, 04:38 PM #6
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Quote:
Originally Posted by nalbertasr5 View Post
My buddy welded mine on for me and is a very knowledgeable mechanic. He thinks it takes a litre of gear oil, so that's what we put in it. Seems to be working well with no metal flakes. It sure is a pain to fill up though! Talk about a bad design. The track bar is now in the way.
The capacity for the rear differential is

2wd = 2.9 qt
4x4 = 2.9 qt with E-locker, - 2.6 qt w/o E-locker
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Old 06-10-2021, 05:51 PM #7
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Originally Posted by nalbertasr5 View Post
My buddy welded mine on for me and is a very knowledgeable mechanic. He thinks it takes a litre of gear oil, so that's what we put in it. Seems to be working well with no metal flakes. It sure is a pain to fill up though! Talk about a bad design. The track bar is now in the way.
Your very knowledgeable mechanic friend left you about 1.5-2 liters low on gear oil if he only put 1 liter in
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Old 06-10-2021, 08:56 PM #8
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Quote:
Originally Posted by nalbertasr5 View Post
My buddy welded mine on for me and is a very knowledgeable mechanic. He thinks it takes a litre of gear oil, so that's what we put in it. Seems to be working well with no metal flakes. It sure is a pain to fill up though! Talk about a bad design. The track bar is now in the way.
You should ask Barnes directly and get their input. Long story short you fluid level is entirely dependent on a number of factors, all of which are heavily (if not totally) influenced by the shape of your differential, most importantly the rear cover. These factors are most notably proper lubrication of the pinion and bearing while also keeping aeration/cavitation to an absolute minimum - both of these are very reliant on the shape of the cover to work as intended, as your cover is what assists the oil in being picked up by the ring gear as well as where aeration will typically begin to form first as oil falls back down or clashes with/thrown against the wall as it's spun. More air means more insulation and more heat, which means less lubrication properties. I'm paraphrasing greatly but videos like this or like this explain it very well, and from Banks too - people that excel in diff covers.
Why did you go with a weld on cover instead of replacing the FIPG if it was leaking, if I dare ask?
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Old 06-11-2021, 12:06 PM #9
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Why did you go with a weld on cover instead of replacing the FIPG if it was leaking, if I dare ask?
There is no FIPG for the rear diff cover. The only seal for the center section of the rear diff is where the 3rd member slides into the front of the rear diff (opposite of the rear diff cover). The rear diff cover is part of the rear axle housing.
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Old 06-11-2021, 12:50 PM #10
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Quote:
Originally Posted by Bad Luck View Post
There is no FIPG for the rear diff cover. The only seal for the center section of the rear diff is where the 3rd member slides into the front of the rear diff (opposite of the rear diff cover). The rear diff cover is part of the rear axle housing.
To add to this a little the Barnes cover is way more beefy than the stock one. Basically it’s like armor for the rear diff..
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Old 06-11-2021, 12:52 PM #11
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Originally Posted by Bad Luck View Post
There is no FIPG for the rear diff cover. The only seal for the center section of the rear diff is where the 3rd member slides into the front of the rear diff (opposite of the rear diff cover). The rear diff cover is part of the rear axle housing.
yep the read diff cover is a weld on. Is barnes the only one who makes them ? Mine is pretty rusty for now I just wire brushed and painted
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Old 06-11-2021, 02:07 PM #12
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yep the read diff cover is a weld on. Is barnes the only one who makes them ? Mine is pretty rusty for now I just wire brushed and painted
Barnes is the only company that I’ve seen that replaces the entire rear cover. other companies just add armor to that section like Marlin crawler/trail gear/ruff stuff.
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Old 06-11-2021, 02:18 PM #13
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Originally Posted by Bad Luck View Post
There is no FIPG for the rear diff cover. The only seal for the center section of the rear diff is where the 3rd member slides into the front of the rear diff (opposite of the rear diff cover). The rear diff cover is part of the rear axle housing.
Oh duh I was thinking backwards, forgot the rear isn't bolted. Got elocker stuff on the brain
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Old 06-11-2021, 04:45 PM #14
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yep the read diff cover is a weld on. Is barnes the only one who makes them ? Mine is pretty rusty for now I just wire brushed and painted
Barnes is the only rear diff cover replacement that I know of. Like others have said they are very beefy. Essentially trail armor.
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Old 06-11-2021, 04:47 PM #15
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Originally Posted by D'arce View Post
I just replaced the leaking rear axle cover with a Barnes weld on unit. The fill hole is not in the stock location, it's sitting way above. Is it considered full when the oil is sitting just below the bottom of the rear axle tube?
From the Barnes installation instructions:

"Fill the differential with the factory recommended weight gear oil. Fill the differential until the oil reaches half way up the ring gear." Step number 13: https://www.barnes4wd.com/assets/ima...structions.pdf
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