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I've changed the gear oil in my '06 F-350 and added new cover, which is supposed to increase my fluid capacity to 4.5 qts. Issue I came across was only 3.25 qts went in before oil came out of the "level" hole in the new cover.
New cover is AFE, with level sight port on side. It shows oil all the way at top of glass, which is when oil started weeping from fluid level port right next to it.
I have additional 3" lift on the truck from factory (front and rear), so I don't think it has rotated any more than stock
When I drained gear oil, it certainly didn't appear that 6.5 pints came out (factory spec for '06 with LS). I did have a pinion seal leak, not sure how much I lost there. It was caused by plugged vent tube. Hasn't leaked since I cleared the plug.
I added enough friction modifier (10 oz) to account for 9 pints versus 6.5 pints.
Questions:
1. Since the AFE level port doesn't seem to be correct for my truck, do I just fill to bottom of the original 3/8" plug at front of pumpkin?
2. How do I tell if I have too much friction modifier? (symptoms)
Removed the factory fill plug...couldn't even feel gear oil level. So I just added gear oil to make a total of 4.5 qts. Gear oil just below the factory fill plug now.
I dont know where it goes...but I have never gotton what was supposed to be in differentals , transfer cases. Engine oil and tranny's seem to measure out close.
I like to run higher than stock myself. Just above the axle tubes My father saw quite a few RVs burn up the drivers side axle bearing. It was due to running dry because of the road camber with straight slow driving. Overfill slightly and failures went away. Stock level appears to depend on axle tilting to "spill" oil into the tubes for bearing lube. Additional oil won't hurt but could cause a small drop in MPG. It is easy to add thru the ABS sensor hole. I try for about 1/4 to 1/2 inch level in the tubes.
Getting the additive correct gets harder with more oil. But seems most add minimal recommended then add until the it stops chattering when turning.