Yeah, for the low cost of RTV and Gear Oil, i would just pull it off and re-seal it too. And with the ease of that drain plug they put on the D44 housing, it'll be even less messy than ever before. I would take a file or grinder to that banged up edge and smooth it out, and maybe even trim a hair off the bottom and give it a tapered edge so it'll be harder for rocks to catch it and rip it up next time. I always like RTV better than gaskets anyway, i think it allow for a lil more bangin around on the rocks than a gasket too. When i grenade the rear end on my TJ ( Dana 35 + 300 HP/375 ft lbs torque + 33x12.50 Mudders + a 300 foot burn out = grenaded rear end) i put the gasket back there cuz i was out of RTV and it started leaking in a day and a half, so i pulled it, RTV'ed it, and it was good from then on. just my .02

 

ThinkMud,...this might help ya, when putting on my Rockcrusher's front & rear on, holding them steady is a bear. The more you move it around after you put the silicone gasket stuff on, the more chance of a leak. What I did was, go to Ace Auto and buy 2 threaded studs of same thread size threaded at both ends(about 2 1/2" long), I put them in each side of Diff & just push Diff Cover flush with no movement at all. Then I just started the rest of the bolts in with my fingers, then took the 2 studs out and replaced with diff cover bolts. Beleive me, after putting the slicone on, theat cover wants to float around and gets difficults hold steady...hope this helps.
[IMG][/IMG]

 

Awesome Idea about the 2 studs Jim, I'll try that next time.

I just put he diff cover on a piece of cardboard and hit the bent in with a hammer and then scrapped off all the old sealant stuff, now it's back on, torqued to about 29lbs. and the rtv stuff said wait about an hour. wish me luck.

and Jim how much were your rockcrusher diff gaurds? and did they have the front cover as well? Thanks.

 

FYI I had the same leak, from "Trail" damage! Had the dealer fix, then went and ordered the Rockkrushers, will have them on later this week. F-the factory ones, I bent one on the first trail ride. Get rid of the tiin foil and step on up. Dave at Northridgeis the man to see!!!!!!.......

 

A tool Like this you won't use every day or even very often unless you plan on really getting into donig a lot of mechanic work. Yould be better off borrowing or renting one if you could.
If you really feel like you need a torque wrench, then get a Craftsman one from Sears because they have a lifetime warrenty on all their non-powered hand tools.

You will probably need to get one that's 3/8ths drive, because most 1/2 inch drive torque wrenches don't start much before 50 Ft.Lbs

Good Luck!

CHOPPER

 

ThinkMud, I think I paid $130 for the set > both the D30- & D44....very heavy & strong, and USGAONE is correct, great service at >>>>>>>>>
((http://www.northridge4x4.com/jk.php)).

 

Same here, I use the BUBBA & BUBBA Torque method also, I just snug them down & then go around & snug again, all feel.

 

Awesome Jim! I was looking for covers and everything I saw was like twice as much! like 130 for just 1 cover. I am going to order 2 sets tonight or tomorrow, one for the JK and one for my girlfriend's Rubicon.

 

Ok Ok ...I'll rub it in!!!!! if you had ordered a few weeks ago it was on special $115 or so for the set (D44's for me) and free shipping! Northridge ROCKS! and Dave is super attentive, and GREAT GREAT customer service!...

Won't bore you all with the details, but There was a slight problem, and couldn't be happier if I tried!

 

Well my girlfriend just ordered 2 sets for us, and I hope they don't mess it up, b/c one for was for 2 D44's and one for a D30 and D44, and the check out page said d30 and d44 quantity 2... so i put in the notes what is is supposed to be and also she just emailed their sales, so i hope they get it correct, and we will both soon have diff covers!