I was just wrapping up changing my front diff fluid in my Dana 30. Everything was going smooth until I was done torquing them down...

I began to torque them at 30ft-lbs, in the star pattern as advised.

As I was done I looked at the wrench to notice that it was at 60! Even though it was locked.

So I went through and individually loosed one and torqued them down to 30. BUT one wouldn't come off as the bolt head + my attachment weren't gripping.

2 QUESTIONS:
Is it bad to have the one stuck at possibly ~60 ft-lbs?

Did loosening each bolt (one at a time) and then retightening ruin the bead of RTV? (This was within 30 minutes of applying the cover)

 

youre probably fine.

 

Sigh... I hope so.

Do you think I should get the bolt that is stuck off tomorrow? Or just leave it?

 

I'm sure you're fine. Full it on up and take it for a drive

 

Since you aren't using a normal gasket, I wouldn't imagine a single over-tight bolt would cause a leak. I believe RTV takes a few hours to set. 30 min shouldn't be an issue.

 

I'm gonna fill it up tomorrow morning and take it for a spin (got some bedliner drying in my driver's floor pan area)

How long would it take for a minor leak to appear?

 

Should I leave the bolt as it is since I couldn't get it off and the RTV is setting?

 

I think you will be fine also.

 

Hmm... I guess in another 30k miles I'll deal with that pesky bolt. (As long as everything holds)

 

Sleep well tonight.