?Removing the diff cover without removing the diff?
 

Has anyone ever managed to remove the diff cover and reseal it without dropping the whole diff?

I just swapped in a low mileage diff and think it has a cover leak. I put new axle seals in before installing it but didnt want to crack open the cover and risk creating a leak. Apparently i was wrong but am trying to avoid dropping the diff back out.

Good luck with that!

You don't have to remove the diff to reseal the cover though. You'll need to undo the diff mount, PPF and let it hang by the axles on the subframe, wiping the dregs of oil out of the bottom of the diff before applying the gloop, might prove prudent, to avoid a repeat.

Thinking ahead, like when resealing the pan it might require some care to keep the mating surfaces clean (oil free) when you reseal it. Brake parts cleaner should work well.

Yeah I think some of the diff slightly sticks through the rear subframe so it could be tricky. The cover can slide pretty much straight down when it's removed.

If you can get to the bolts and if it looks like you have enough room to slide out the cover it may be possible. If not, you could remove PPF and unbolt diff mount to have it sag down for access.

Dale

Edit

After dropping the PPF it might be worth it to just remove the driveshaft. That should allow the pinion to swing up and give you enough clearance. If it works it’s a lot easier than disconnecting the diff mounts.

If you're talking about an FD, I installed a large capacity Greddy diff cover a few years ago.
Seem to recall it being a tight fit, but pretty straight forward.
drain it
remove bolts
remove cover
clean gasket surface
apply sealant
install cover
fill diff