sreeb

I have a c8.25 sitting on my workbench that I am rebuilding.

I keep looking at the tab that sticks down from the bottom of the differential casting and wondering if I can cut it off to gain ground clearance.

Obviously I can but what bad thing will happen if I do?

Rogue4x4

I don't think a 1/4" of extra clearance will do much for you. Seems like a lot of work for little gain. It was designed that way for a reason. Removing it may weaken the structure of the pumpkin, and make it more prone to cracking or breaking if you smack it on a rock on the trail. That little bit of extra gusseting probably prevents that, and if you ever get rid of it, you'll only confuse people down the road into thinking it may be a D35, that little lip is what you look for when trying to ID your axle...just my .02

SteveMongr

Oops.. I trimmed a bit. For me it drags sand and tree stumps on 31" tires. Hopefully the cast iron cover will help compensate for any strength compromise.

gpXJ

Another solution would be to take a piece of 1/4" plate and weld a ramp from the lip of the lip back to the housing. That way you don't weaken the housing and you can still slide up and over stuff.

SteveMongr

That was my first idea, also incorporating a pinion guard. But a basic plate like you mention would be simple to do and effective.

s14unimog

For me that stupid little lip has been the reason for more than a few hangups. I trimmed mine down a bit - I say it's worth doing.

sreeb

It is a full 1/2" to the sealing surface.

Rogue4x4

Oh, well carry on then...LOL

Rogue4x4

You are also using a MUCH beefier cover. Not the stamped steel original. OP, are you upgrading your diff cover?

s14unimog

yeah... and?

sreeb

If possible, I plan on using the OEM cover.

It is clear that cutting off tab will have some impact on strength. I can't tell by just looking how important it is.

I don't know why it was put there in the first place. It could be a critical structural element or it could be an easy way to index the casting for the initial machining operation.

There isn't as much info on the web regarding modding the c8.25 as there is for some other differentials.

I'm hoping to get the benefit of others experience here.

So far, two people have done it without problems so far. Both used aftermarket covers.

Even with the aftermarket covers, this seems by far the cheapest way to get an extra 1/2" of axle clearance.

s14unimog

I suspect you meant without problems. It's definitely a structural rib for the case, but I can say with some serious offroading/abuse, the rosette welds for the axle tubes will fail long before one cracks the case or sees enough case deflection to damage gear tooth engagement. Fear not; shave it off.

hawkmantn

What problems are you talking about (that the two people had even with aftermarket covers)? I'm also looking to shave up to the gasket surface and already have a riddler cover.

sreeb

That was a typo. Fixed it.

XJmike0122

Shave it and get a Ruffstiff dif cover. http://www.ruffstuffspecialties.com/...ode=diffcovers