So I took off my diff cover and found this on the mating surface. Hit it with wire brush and sanded it alittle until flat. It don't want to sand it anymore and make the surface uneven...any suggestions.

 

That looks like a bad casting from the get go. Have you had issues with leaks?

If not, I would leave it, and just add some extra sealant there when you button it up. In that situation I would also recommend a paper gasket...just in case...put sealant on the cover, then the diff, add paper gasket, and bolt it up.

Best I got for ya. I wouldn't try to go down further with a wire wheel or flap disc, you don't wan't to create an even lower spot there...

 

Ran into that when I did the rear disc upgrade. Cleaned the surfaces of the rear and cover. Then I used Indian Head Gasket Shellac on both surfaces. Installed the gasket and no leaks. I know if it comes time to take the cover off cleaning the surfaces will take some time but no big deal. Used this gasket:
http://www.rockauto.com/en/moreinfo....180314&jsn=444

 

I actually am not having a problem with leaking. I bought a lube locker gasket which is reusable. I'm going to use it as is....if it leaks I'll rtv. Thanks guys. On the bright side this bad boy is a new addition. Cant say enough about the quality of ruffstuff diff covers.

 

I wouldn't think you'd have a leak problem. Surfaces that the gasket covers looks good. Mine never leaked before either.

Hvy duty looking cover.

 

Good deal. I run the Lube Lockers as well. And, RS makes a good product. Those guys are cool too. Sounds like you have it under control.

As to my earlier statement, looks like a bad casting, they're cast, then machined down to get the surface...yours looks a tad shy...but, hey, no leaky, no problem, right? LMAO

 

Thanks again guys. Just wasn't sure. I will get to getting the covers on now.