I've read 30 ft/lbs is too much for diff covers
 

As you can tell, I'm about to do my 30K fluid changes myself and doing a lot of searches and asking several questions. I've read many posts that 30 ft/lbs of torque is too much for the differential covers because the bolts like to break. What I haven't found is what is a safer torque to avoid breaking bolts but not allow leaks?

Thanks to this site and everyone answering my questions. I'm looking forward to doing my own maintenance.

Well, for some reason the bolts are evidently a little weak. I can't remember if they are originally installed with loctite or not, but I always run the bolts that have loctite on them through the brush wheel on my bench grinder and apply new. As for leakage around the diffs, I haven't noticed much more than a little blush of oil halo around the bottom diff bolt. There have been others that have posted breaking them off when wrenching them down though. I would think if you wanted to really torque them down, maybe change to a higher grade of bolt? You should be good to go with no leaks at 30ft/lbs though. Hope this helps.

When I had my 03 there were threads about breaking bolts, so I carefully removed all the old thread lock and got them all at 30 ft/lbs. I figured I must have gotten good bolts and wouldn't have any trouble.

On the 2nd change, though, one of the little buggers snapped off. The head just popped right off when the bolt was just snug, not even close to 30 ft/lbs. Fortunately mine was like everyone else's seems to be, in that the bolt was easy to extract.

The last couple times I've just snugged them down by hand, probably about 25 ft/lbs, and I haven't broken a bolt, and haven't had one even seep...


Anyhow, bottom line: I'd go for about 25 ft/lbs with the old thread locker removed and use some blue locktite. Other than that, it wouldn't hurt to have a spare bolt, some left twist drills and bolt extractors laying around in the garage...

I have always had good luck with diff and valve cover bolts by tightening with a ratchet but not using the handle, just grasping the ratchet head and and tighten with medium pressure. Sorry I can't explain it better, but I haven't snapped a bolt off since high school auto shop.

X-2 on that......I just tighten them to the point where I don't think they will leak (or break, or strip). Then check for leaks, in a few days check for leaks again.

Are you sure it's not 30 inch pounds (vs) 30 foot pounds. There's a huge differance, besides its only a cover your snugging down... Sounds a little excessive

Differential Cover Bolts 30 ft lbs. That's correct torque value. Never broke a bolt yet.[coffee] but there's always a first time.

When I changed my diff fluid I also installed the MagHytec covers. I read ALL the threads about the 30 ft lb torque issues and decided to lower it when I torqued them. I torqued mine at 20 ft lbs and they are doing just fine, no leaks. Since I was using new bolts that came with my cover and they were a better grade I probably could have gone to the 30 ft lbs without any problems but I did not want them down the road as it seems they break on removal more often than installation.

CD

On my diff covers I just used Good and Tight on the bolts and neither one has leaked!

I usually go German Torque, but IIRC, but you can always go by a fastener torque chart.