I just got through checking the fluid levels in both differentials as you guys have suggested. Like you all mentioned, a quart short in the rear and 1/2 pint in front.

As far as draining the fluids goes, do you just loosen up the 3 or 4 bottom bolts and let it drip out that way or do you have to take off the entire cover?

Thanks

Ron W.

 

If you read up on the american axle threads, I think it was concluded that they are NOT short on fluid from the factory, that in fact american axle on this particular unit, doesn't measure the 'proper' level at the bottom thread of the plug, it's actually supposed to be lower... Some guys can chime in on this , but I believe it was all a scare...

 

That's the first time I heard that. I thought the manual said it should be filled to the bottom of the hole?

 

I think the manual said 1/4" below the hole; +/- 1/4".

No matter, my diff was was ALOT lower than that.

Mine is at the bottom of the hole now.

 

9.25 Front: 1/4" +/- 1/4" (Total of 1/2" below fill hole)
10.5 Rear: 3/4" +/- 1/4" (Total of l" below fill hole)
11.5 Rear: 1/2" +/- 1/4" (Total of 3/4" below fill hole)

 

[quote author=bulabula link=board=20;threadid=19803;start=0#msg186378 date=1063904002]
I think the manual said 1/4" below the hole; +/- 1/4".

No matter, my diff was was ALOT lower than that.

Mine is at the bottom of the hole now.
[/quote]

What happens if you overfill? Does it leak out the vent hole, or does it find it's way past the diff seals? Does it 'foam" reducing lubrication in the diff? Does it foam more if it is too low?

 

Found this on the TDR - straight from American Axle -

American Axles

Dodge Trucks are now using American Axles for 2003 and later. Please make sure your Service Department is using the correct lubricant and adhering to the correct fill levels.

These axles do not require Friction Modifier, but do require a special synthetic lubricant. According to American Axle, this 75W-90 lubricant part number listed below is a pure synthetic lubricant and does not contain Phosphates. This is different from the 75W-I40 that is used on DANA and Corporate Axles.

Please use Mopar Part # 05102232AA on all American Axles

Caution: Overfilling these Axles may result in lubricant foaming and overheating!

Please adhere to the fill levels described in the vehicle owner's manual or levels listed below.

9.25 Front: 1/4" +/- 1/4" (Total of 1/2" below fill hole)
10.5 Rear: 3/4" +/- 1/4" (Total of l" below fill hole)
11.5 Rear: 1/2" +/- 1/4" (Total of 3/4" below Fall hole)


Reminder
 A break in period of 500 miles is required before towing!
 Afterwards do not exceed 50 MPH for the first 500 miles of towing.


...
Dana & Corporate Axles
Both of these axles require the 75W-140 Synthetic lubricant available through Mopar Parts when used for towing. (See Owners Manual)

 

meaning the MAX fluid level in the rear is 1/4" below the hole

 

good to see renewed interest in this, as I had quit chiming in cause I didn't think anyone was listening. I spoke with AA directly -- their quality manager in charge of the DC/AA relationship. with respect to the AA axle situation:

1. absolutely, the vast majority of "low lube levels" in the 03 axles were incorrectly diagnosed. the unfortunate reality is that, while the rest of the world uses the fill hole as the level indicator, AA does not.

2. AA mfgs several axle products with the same cover, each having different internal geometries and fill requirements. the fill hole is mfg'd into the cover in the same place for all covers, and so various axles using that cover will have different fill levels, when the fill hole itself is used as the indicator.

3. The AA guy told me there is no problem in the 11.5" axles filling them up to the brim. this deserves some clarification and further scrutiny but thats the latest info and recollection I have. for this reason I have previously recommended 'fill to the brim' just to avoid all question, and that there is every advantage and no disadvantages to doing this. seeing the spec posted by lightman, however, it appears that filling to the brim might not be the best. Still, I would fill to 1/4" below the fill hole, given this spec.

4. There were some quality problems in the AA axels esp during the early intro of the 03 trucks. these quality problems had to do with improper setup and were mfg process related, not parts quality or fill level related. the proper amount of fluid was installed by the factory on a volume basis (# of quarts) and the fluid level with respect to the fill hole was never inspected nor prescribed (within the AA factory) as a method of verifying proper fluid level.

5. early on in the 03 model year, there were some unfortunate communication breakdowns between AA and CD with regards to how the axle failures should be handled. This resulted in a great many "low lube" diagnoses that were incorrect. Additionally, some DC techs would put the wrong fluid in, and in some cases add (undesireable) friction modifier which was appropriate only to the 2nd gen Dana axles.

 

Interesting. So...how do you check the level? I haven't looked at it, but if I recall correctly from other diffs I've worked on you can't just look in the fill hole and see what the level is. Too dark in there to see anything. Are you guys just adding more oil until it reaches the fill hole or what?

 

and you guys thought I was crazy ;D

 

Remember...there is no dumb question. At least that's what I keep telling myself...

 

I would beg to differ, I tend to ask dumb questions all the time! ;D

 

Then you should be able to relate. ;D

 

This is a great thread! So how DO you check the level? Also, I have a 2500. Do I have the 10.5" or 11.5" rear diff??