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Possibly overfilled? If it doesn't have space to expand while heating up it goes out the breather. With aftermarket diff covers they usually hold more fluid which helps keep it cooler though. So that wouldn't happen as easily. Overheating gears usually makes the diff puke fluid. Could be a bearing went out same time as the cover change. Seems pretty unlikely though. Maybe open the diff back up and double check something isn't going out. As bad as that sucks at least you'll know for sure.
True that does suck. I keep the diff a little over full on purpose because of the angle I have the pinion at, but it never puked oil outof anything till I put this cover on. the vent is a good 24 inches away from the diff. Just does'nt make any sense at all,
How are you over filling it? I filled mine out of the truck years ago before I bolted the cover on and ended up with too much fluid once it was positioned under the truck. First test drive puked fluid out of the breather.
When I changed the cover I had the rear of the truck jacked up, combined with the angle of the pinion when I dropped back on the ground, Whahlaa! over full. I guess whats got me so perplexed is the distance it's pushing the oil up the vent. And when I checked it yesterday it was slightly low.