i was tightening my spring bolts into my diff cover.. and guess what..

had the torque wrench set to 40 lbs..  i planned to cinch them at 40, then 55, then finally 70 lbs..

the threads popped on two of the bolt holes at 40 lbs

damn it.. now i have to buy a cover.. anyone got one they will sell cheap ??

seen them for $85 from Muskegon.....they make it I believe. The others resell same part for more.

mine busted too, that's why I always recommend putting a new one on ...it's just too easy for the old POS to break. Mine was cracked and this could not be seen from the outside...so had to rip everything back again. Did the same thing...walked it up 10 lbs at a time until it let go at 50.

I think the arch in the spring makes it even harder on this part. Should have weight on it to flatten it out before you start tightening?????

I stopped at 60 lbs before I got scared.....should be 70????

I went ahead and bought a new HD cover..  since the part is no longer original I can put a drain plug in.. 

I usually do so but didnt want to on my "original" cover..  since that is no longer an issue i can mod away..

i figure if cant straighten the spring with 70 lbs of torque then i really cant trust it under the car..  but im using a fiberglass anyway..  no real straightening to occur..

[QUOTE=kstyer]When the bolt holes strip, but otherwise it's okay, you could use a helicoil or thread insert to repair the hole.  Complete replacement is not necessary. [/QUOTE]

they are 9/16ths..  and i cant find a helicoil that size..

and standards keenserts are too big..  really wouldnt leave much metal...

no thinwall keenserts in 9/16th..

I think I have the same problem here with 1 bolt on the front passenger side of the differential cover. It had four washers on it. I had fluid pouring out when this bolt came off, now when I tighten it down I am still noticing fluid. suppose I am SOL? Is the shield really needed to be put back on? I guess the bright side is I already seemed to have a problem with the rear end making a noise and I was preparing to address it but had hoped to do it in my time not the car's time!

Does anyone know of any temp. fixes I could do to get the leak to stop so I can fill the differntial? I am wanting to drive it around a few blocks and see if I need to replace it also?

gene... you need a new cover.. no ifs ands or buts..

Yes, I know the cover is shot. Wondering my options for a rebuilt differential ( changing ratio also). I still have't proven to myself the differential is history. It looks like you can get the whole assembly with cover and yolks. I don't think I will enjoy doing the rear end and I would like to do it only once.

I don't mind installing new parts when I am upgrading.