I like to omit the gasket--cause I find it to be a pita. I could use it--but rtv alone has always worked for me so I just skip it.

Update: I did get the new cover--for the cost (Dorman 9 bucks) I did not even want to spend time cleaning that rotten one. Unfortunately, I could not get the fill plug out. Funny thing is, the fluid was changed about 4 or 5 years ago, so it's not like the plug has been in there for 12 years. I had a shop do it back then as I did not have any time to do it myself. Maybe it is over tight--but I'm guessing it is just corrosion. I really reefed on it too. I did not want to strip the plug out. Tonight I'll warm it with a propane torch and see if it will break free. Thanks you guys for all of your feedback. Wish me luck...looks like I'm gonna need it.

Also, I'm thinking about a bit of anti-seize on the plug when I'm done. Wuddya think?

 

nothing wrong with that where you see a lot of road salt and snow. just make sure that you get it good and tight. i would check it at your oil changes as well.

 

The plug finally broke free with heat and a good deal of muscle. Got her all buttoned up and it's looking good. Thanks for all of the replys.

BTW: G80 listed on the RPO--but not fully locked. Looked like a locker in the diff. I have read where GM listed the G80 code for some vehicles that were not locked full time.

Also, there were very small burrs around the circumference of the ring gear. One at each tooth depression. There was only a small amount of metal shavings on the magnet.

~wheeliemay