I went to the hardware store (Ace is the place!) and picked up 5 replacement bolts that were 1/4" longer and after replacing them 3 days ago the diff has been bone dry. I'd suggest doing that and not even fooling with those torx cap screws.

 

holy goodness, pop the cover scrape the rtv off wipe it down fresh bead of the same. stick the cover on mount your diff skirt on thread the bolts on crisscross pattern , let the sealent set for a 1/2 hr or so fil err up with the gear oils cap it and motor on... warrenty issues jeez what happened to the good ole days just do it

 

Actually, I later found out that his wasn't leaking like we thought it was. When he installed the skid plate, he then topped off the fluid and it over-flowed and ran down into the "valley" created by the skid plate being mounted on top of the diff cover....so the fluid we thought was a leak was actually the fluid that was sitting in that "valley" that was seeping through the crack and onto the ground. Ooops.

 

Ok i put on a warn skid and filled the dif with 1 qt of oil and it over flowed.. should i recheck it in a day or so? its a d30. i figured it would take 2 qts?

anyone else have the amounts?

 

...front and rear 4X Doctor (Dana 30 & 44 ) diff protector without removing the cover...less than an hour, no leaks, no fuss...no muss. I suppose it helped that I had less than a thousand miles on my '08 JK, and had not off roaded or damaged the undercarriage yet.