Last weekend I installed the Rancho differential covers (RS6209 - Dana 44) on the front and rear differential housings of my stock '09 Unlimited Rubicon, due to a mishap with a leaking stock cover (yes those stamped ones really can peel back and leak fluid). I'm a fan of the aggressive look and the separate fill and level holes.

Unfortunately, on the rear its rubbing from the track bar on top left rib on the left side corner, about midway down, from normal driving. So far it seems to have taken only the red powder coat off (leaving a black paint [primer?] below).

I articulated the rear axle slightly to test, and the track bar is positively contacted to the diff cover. I'm concerned that going off-roading and articulating harder could cause damage to the track bar, track bar bolts/bushings, and/or the cover. When the vehicle is sitting on level ground, I am unable to fit my finger between the track bar and diff cover (at the rib) - they are so close.

The front is not rubbing from normal driving (I can get a finger in between there), but I am still concerned that while the axle is articulated it could hit as well.

I realize the note in the instructions "Minor contact with other components may occur at full compression", however this occurs during normal driving (on the rear). This marks my first mod to the vehicle, so the suspension, tires/rims, is all OE. I'm really disappointed that the diff covers won't clear the OE set-up.

The only solution I have come up with is to grind the rib down and test the articulation until it will clear. Of course, this will destroy the nice powder coat in that section. I think this might be a lot of grinding... if I am picturing this right, the track bar will pass close behind the diff cover almost half-way down when articulated. Any other thoughts, aside from an after-market track bar? I don't suppose anyone has pics of a stock track bar articulated across the axle (trying to get an idea of worst case)?

These pics are all the rear, sitting on level ground:







I can say that it is much thicker and I believe much sturdier than the stamped stock cover. The powder coating is nice, no issue with the bolts (they are 12pt). If it wasn't for this, I would be very pleased with the product.

Wanted to make everyone aware, as I have seen some other threads regarding aftermarket diff covers contacting the track bar...

 

You could get a teraflex trackbar bracket that would reposition where the bar mounts no the axle side. It would raise it up enough that it woud clear the diff cover.

 

Just grind it.

 

Do you have the p/n for the axle side mounted one? And, since these brackets are usually to re-center after a lift, is it designed for stock height. I don't want to off-set the axle.

I'm still leaning towards grinding, but trying to get a rough idea of how much material removal is required.

 

Well, finally got an opportunity to get the cover ground down. Prior to fixing the diff cover, we installed the TF leveling kit, which helped the situation a bit.

As you can see, some of the ribs had to be ground a bit for the track bar to clear. Tested articulation after (to bump stops), and now seems to be ok! Just need to paint it red (currently just has a clear coat on).

 

Man, we need to clean that up. It doesnt look that dirty under there until you look at the pics. And we need to get some paint on that puppy! Too bad it didn't work the first time...I would've hoped/thought that Rancho would design it to work with the stock track bar location. Boo.