Front diff cover replacement w/engine out

[Mesozoic]

Just curious if anyone significantly more familiar with these vehicles can speak to whether the front diff cover (currently stock) can be removed and replaced with an aftermarket unit (a G2 in my case) without following the standard procedure of removing axleshafts and dropping the diff, since the engine is out of the vehicle currently and seems to provide some extra space to work on it.

Cheers!

 

[410Fortune]

Nope
You have to drop the diff
The cover will not clear the ring gear
Pull the cv axles, drop the two 10mm and the one 13mm and the diff is out

 

[Turdle]

Will that cover clear the crossmember when installed? Looks ribbed, tight fit.

 

[CDW6212R]

I hope it fits too, it's tight there for the stock pan. It would be nice to have a drain plug. I've thought of drilling a hole in the diff/housing to place one.

 

[410Fortune]

I have never attempted to remove the stock cover because looking down in there access to the bolts and getting it back in place cleanly, it’s just not worth it
It takes just a few to pull the cv axles (at least pass side) and drop the diff out.
Good time to replace axle seals too


Not much space between frame and diff front cover that is for sure!

Drain plug would be nice

 

[CDW6212R]

I looked and saw there are several D35 covers now, most look bigger externally or have poor inside shaping(there should be a nice smooth pocket for the ring gear like OEM. I've wished Banks would make an 8.8 cover like their others they make, so far no bueno.

 

[Mesozoic]

I've had one of their Hammer series covers for ages from when I installed one on the 8.8 out back, merely because it has the drain plug. I figured that with 150,000 miles on the vehicle, the fluid must need a change and I bet there's some efficiency to gain by running a quality synthetic one at that. You're all right though, it's really darn tight in there. That G2 casting might be a bit fat to fit.

G2 AXLE & GEAR | HOME

www.g2axle.com

 

[CDW6212R]

It is AL though, if it's close you may be able to clearance it some. There was a steel version by some brand I'm not familiar with, Rugged Trail maybe. That one also looked kind of compact(outside), but if it didn't fit, that'd be hard to work with. I'm watching your work with that G2 model and see how close it is to going in. The drain plug would help a lot, it's not hard to fill the stock carrier with the OEM side plug.

 

[Turdle]

I powdercoated one red once, still couldn't get anyone to look at it. For what that is worth. Can't really see it anyway. I would not grind on an expensive cover.