I'm going to install a solid diff cover on my dana 30 using gasket sealant. Do I need to wait any period of time after putting the cover on before I fill it or drive it? Also I've read the project jk write up and was wondering if there is a difference between a d44 and d30 gear oil capacity? The write up instructs a specific amount of fluid for the d44 and warns against over filling and making a mess out the breather. Is the ole finger in the fill hole method still acceptable with the higher fill hole on the aftermarket cover?

 

I installed ARB covers and used 1 qt up front in D30 & 1.75 qts in Rear D44. If you have Limited slip in rear you will need an additive. I used redline synethic in both and didn't need the additive.

 

Regarding the use of silicone as a gasket, just let it 'tack up' for about 20 minutes and don't put a huge amount on. The more you put on the cover, the more will squeeze out when you tighten the bolts. About a 1/4" ribbon of the silicone is all you'll need. You can add the gear oil after with no problem. As far as the oil capacity, I filled mine to the fill plug hole and when it started to leak out just a bit, I was done. Just make sure you really clean the cover and differential gasket surfaces with a scraper and some solvent like acetone or equivalent before putting on the silicone.

 

Picture of my ARB diff covers