Fluid level after installing Barnes rear axle cover...
- Thread starter D'arce
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bmason8159
New member
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.
nalbertasr5
New member
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
Your very knowledgeable mechanic friend left you about 1.5-2 liters low on gear oil if he only put 1 liter in
Devbot
New member
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?
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.
T4topher
Member
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..
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
T4topher
Member
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.
Devbot
New member
Oh duh I was thinking backwards, forgot the rear isn't bolted. Got elocker stuff on the brain
Barnes is the only rear diff cover replacement that I know of. Like others have said they are very beefy. Essentially trail armor.
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/im...ferential Cover Installation Instructions.pdf
Going to be hard to tell what's halfway up the ring gear by looking through the fill hole. I have a spare axle assembly I'm going to sight a line across the axle tube to the fill hole and see if I can make some kind of depth reference for a dipstick as mentioned earlier. The fluid capacity should change very little I'd think from stock. I'll start with 2.9 quarts and see what happens. Excited to get this beast back on the road.
MarkamisPrime
New member
Your over thinking it.
More fluid = less heat
Just fill it as you normally would and call it a day
More fluid = less heat
Just fill it as you normally would and call it a day
Yeah I agree. I dumped in 3 quarts and call it good. While under the truck I noticed I was a quart low in the t case. Now I have to check everything lol.
