Ring Gear Hits Differential Cover

[kaufmanj]

When I bought my 1991 k1500 2 years ago, the previous owner just had a local shop help him put in a new rear end. I think it was all done to original stock specs and gear ratios, etc...but I am not positive. Since then, I have gone through 2 differential covers because the ring gear hits the differential cover and slowly wears a hole in it.

 

What can I do? I am confident that I am using the correct stock replacement 10-bolt cover. Could it be something wrong inside the differential? Or, does anyone make a bigger cover with more clearance?

 

I appreciate anyone's help or advice. Thanks!

[Bostonsfavson]

Read this.

[kaufmanj]

I don't think JB weld is a solution. The ring gear is rubbing the cover so hard, that it is actually denting the differential cover. Weird thing is, it made noise one day for about a minute, but other than that, you don't hear anything. Thanks though! Any other ideas?

[Genuinefine409]

I don't think JB weld is a solution. The ring gear is rubbing the cover so hard, that it is actually denting the differential cover. Weird thing is, it made noise one day for about a minute, but other than that, you don't hear anything. Thanks though! Any other ideas?

 

 

can you post/send any pics?

[Zembonez]

I don't think JB weld is a solution. The ring gear is rubbing the cover so hard, that it is actually denting the differential cover. Weird thing is, it made noise one day for about a minute, but other than that, you don't hear anything. Thanks though! Any other ideas?

 

 

can you post/send any pics?

 

Sounds like very little additional clearance is needed to clear the gear.

 

I'd fix it... create a "dent" from the inside of the cover for clearance. (ball end of a hammer with the cover in sand works well) Once the new area is there to clear the gear, weld the hole up, grind it smooth, paint it and never look back. Problem gone.

 

Another possibility would be using one of the aftermarket "extra capacity diff covers. Really depends on how creative you want to be and how much $$$ you want to spend.

 

I have no idea why it hits in the first place. Possible aftermarket ring gear... different ratio?

[kaufmanj]

I like the hammer it out, weld, and paint it idea. That sounds like it would work well to me. Thanks!

[Genuinefine409]

Is it possible to bolt the cover on wrong? The cover is bulged out for clearance of the gear. It's a wonder if its hitting the gear enough to wear a hole in it that it doesn't leak and you are getting a good seal. the bolts look like you could flip the cover around and put the bulge on the opposite side of the gear, that would definitely cause the gear to hit it.

[C & A s Dad]

Just a thought. You may have a carrier bearing issue. If they are worn, you may be getting some mvt in the ring gear.

[Genuinefine409]

Just a thought. You may have a carrier bearing issue. If they are worn, you may be getting some mvt in the ring gear.

 

I was thinking that as well. You'd think there would be some noise though.