I picked up an Chrysler 8.25 cover from an 08 Durango for free.
The cover is HEAVY cast steel? AND the fill plug is a good 1" higher than the original stamped metal cover from the XJ 8.25 I am using,,

 

Cast iron probably, but still a good buy, especially for that price

 

I finally went to the yard today and grabbed one of these. To be honest, I'm not entirely sure why I need it, but I just love doing parts swaps like this. The only thing it will likely do for me is add weight.

Anyways, just be on the lookout for a 2004-2009 Dodge Durango or Chrysler Aspen in the junkyards, then check to make sure the axle is an 8.25. You only need a 21mm wrench/ socket for the Watts linkage bolt (its tight!) and a 13mm for the cover bolts. 13/16" and 1/2" will work as well. A prybar to help lever off the diff cover helps too.

Make sure to take the bolts with you as well! They are significantly longer than the XJ's bolts.


Pull these two alignment dowels off and it's ready to install.


Making sure it all clears.

Thanks for the info Slackdaddy! I'm hoping to have this installed tomorrow as part of my axle swap.

 

So what's the deal with the different fill levels, the Rango being an inch higher than the Cherokee? Are the two type of axles tilted at different angles, thus accounting for the different fill plug heights?

 

Upgrade to a magnetic fill plug. I have on mine.

 

I wish I had looked at that while I was in the yard. I'm not sure how much of the fill plug height difference is due to angle and how much due to the engineers expecting a higher load on the bigger Durango.

Either way, I slightly underfilled mine during the install. I put in just over two quarts, but I did this as part of a Truetrac equipped axle swap. That may take up more volume in the diff than the standard open diff.


Also, I sanded down the cast finished internal surface with a flap disc. My hope is this will improve internal fluid flow around the gear and reduce heat buildup. A smoother internal surface should result in lower shear forces in the gear oil.


It looks really good under there!