OK, so it's safe to say I overfilled it. The fill hole on the cover is at the same level as the stock hole on the rear end.

Does this mean the seal is bad? or did it leak out because it was overfilled?

If it's bad, I won't be changing it myself. I'll take it back to the guy that installed the truetrac & gears. But, I don't want to drain it & refill it, only to have it drained & refilled again if the seal is replaced.

 

Just copied this from the TA website:

All Girdles increase fluid capacity approx. 1/2 pint.

I was thinking it was a 1/2 quart. Guess I did overfill it.
I'm gonna drain it, refill with 2.5-3qts of 80/90, clean it up & hope it doesn't do it again.

I just looked at the mag-hytec cover & it adds an additional 2 qts

 

Jegs has their version of this cover & you can buy it as a kit which includes only 2 qts of oil. Maybe 3 qts is too much?

Anybody have their owners manual nearby? I'm at work & the truck is at home.

 

update:
So I started with 4 qts of 85/140 about a month ago. no high speed driving until this past weekend.

I drained 3 qts out of the rear end, even alternated jacking the truck up on both sides to try to get as much to drain out of the tubes as possible. Looking at the underside of my truck, it's safe to say that at least a qt sprayed out on my trip last weekend. I feel sorry for anybody who rode close behind me as I myself have a light coating of gear oil/grime all over my tailgate.

I checked the owner's manual & it did not give a capacity other than saying fill to 5/8"-1 5/8" below the fill plug on the side(for the 10bolt). Going off of that, the gussett on the side of the rear end, just below the fill hole, is about in the middle of that range. I made a dipstick out of a coat hanger, but the fill hole is big enough that you can put a finger in to check the level.

I put 2 qts of 80-90 in & that made it about 5/8" below the fill hole.

The fill hole on the TA cover is about 1/2"-3/4" above the factory fill hole.

Just in case anyone was wondering

 

I think I put a gallon in mine...granted its a 14bolt with a bigger cover. I use the fill hole on the cover and a gallon puts it right up to the top....the pinion seal shouldnt blow out, might want to check and make sure the breather hose is not clogged or something. Its there to relieve pressure so you dont blow out seals.

 

i got money on the seal. you can actually break the seal by rushing. once you take the pinion nut off you have to put it back the same way (torque wise) all you need is a hammer, a big flat head, a 2x4. pretty simple install, i wanna say its a 1 3/16" socket or a 1 1/16" i cant remember

 

Is the vent unobstructed?

peace
Hog

 

the seal is fine, it's not meant to hold back fluid sitting against it like that. the normal amount of gear oil that contacts it is simply splashed up from the ring gear. the seal should be perfectly fine, just clean your truck and add the right amount of gear oil from the factory fill plug.