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Old 08-10-2010, 10:59 AM
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HOW TO Differential Cover

Hi heres a little how to, for the people who whats upgrade the differential cover, for the Dana 44, heres some info about who covers use this ones:

Jeep WK SRT8 06-09
Jeep WK with 2WD Hemi 5.7 05-09 (limited and overland)
Jeep XK with 2WD Hemi 5.7 05-09 (limited and overland)

Tech Info: Dana 44(226RBI) /226mm 10 Bolts

Or more easy get down and take a look, and your differential must look like these ones:




So rust so ugly, so i been searching on internet about differential covers for the famous Dana44, there are many brands like Rancho, ARB, and others but they claim to dont fit our jeep, not aluminium Dana44, so they offer for off road jeeps. They are so kind of covers that goes over the oem ones,but it looks like my chrome handles LOL

So theres a company www.yourcovers.com that sales one for our application. I get one.

1: Remove the traction bar, if dont, you can not install the new cover, you need 22mm socket or wrench. The drivers side come little tricky to remove the bolt, obstruct the suspension spring, but use some jack to lift it up.



Then position oil drain pan (minimum 2 quart capacity) underneath your oem differential cover.

2: Remove cover bolts (13mm socket), start from the lowest one, the top one, dont remove it complete.

3: Hit the cover with a gromet hammer, its is little hard to breake the seal, use a putty knife or gasket scraper but be careful not to gouge the gasket surface of the housing, allow the oil to drain. Then hold the cover and remove for complete the last upper bolt.

4:Remove all old gasket material and oil from the machined gasket surface of the differential housing, with some plastic scraper, please dont use metal against metal that produce warpage. Also try to clean the gears with some towels or use breake cleaner (it wont hurt the gears), let everything dry.

5: Apply RTV Gasket material to the machined gasket surface of the differential housing. Ensure that the sealer bead is laid on the inside of the bolt holes. The bead is not to pass through the holes or outside the holes. The bead is to be 1/8" to 1/4" high and 1/8" to 1/4" wide.
I use Permatex Ultra Black p/n 82180 also exist the Ultra Gray p/n 82194, the black is more expensive but i found it at same price than the gray.,



The RTV bead must be apply in the middle of the machine gasket surface and with the finger in circular movements, spread the RTV to eliminate some air bubles. Inmediatly go and install the new cover.

6: Install the bolts with hand tigh, use some medium strength treaf locker to prevent them from loosening.

7: Torque the bolts in a criss cross pattern, a little at a time. This will make a perfect seal. Torque flange bolts to 15 ft-lbs (oem bolts 30 ft-lbs), Drain Plug to 20 ft-lbs (oem draing plug to 44 ft-lbs).

8: Allow at least 1 hour to cure the RTV gasket, i leave it for 6 hours. Fill the new cover. OEM cover capacity is 76oz(+-2oz), so the yourcovers i use .7 quarts more of capacity that means 22.4 more oz, must be 98.4 oz (+-2oz) of capacity, but i fill it and start to get out from the filling hole, i let it to drain the excess for 2 hours, so the i can say the exact capacity is 94 oz (1quart=32oz), finally install the fill plug with some RTV on the treads, and torque it to 12 ft-lb.

I use 75W140 Royal purple oil, for the dana44 is not need it ELSD modifier oil, because is not a ELSD, but if you have another differential with ELSD people recomend add 8oz of that modifier fluid.

Reinstall the traction bar and torque it to 120 lb-ft.

Leave the RTV of the fill plug cures, 1 extra hour, lol i got nothing that time.

Features.

Extra capacity.
Nice Look.
Cooler oil.
Stronger than oem.
Chrome i like chrome in black jeeps.
Magnetic drain plug collect some metal if exist.
Drain and fill plug, well the oem also have ones.







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Old 08-10-2010, 11:15 AM
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Re: HOW TO Differential Cover

looks so much better than before +rep
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Old 08-10-2010, 05:13 PM
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Re: HOW TO Differential Cover

Looks Great! Not quite the same but this was the Riddler MFG D44 Off Road Diff Cover I had in my old XJ.

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Old 08-10-2010, 05:21 PM
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Re: HOW TO Differential Cover

looks awesome!
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Old 08-10-2010, 05:44 PM
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Re: HOW TO Differential Cover

Whats a good OFF ROAD diff cover for the WK as well by chance?

Also, nice write up + nice pics.
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Old 08-13-2010, 12:15 AM
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Re: HOW TO Differential Cover

Looks good! Makes me want to drop the $200 on the new diff cover too.
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Old 08-13-2010, 09:24 AM
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Re: HOW TO Differential Cover

Nice write-up. Just be carefull, because there is the dana 44, and like my wj there is the 44a. Completely different cases. And it blows!

I want my rear diff to match my front.

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Old 08-14-2010, 08:26 PM
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Re: HOW TO Differential Cover

Quote:
Originally Posted by maxst2 View Post
Whats a good OFF ROAD diff cover for the WK as well by chance?

Also, nice write up + nice pics.

if you have a D44 rear axle in your wk there are a few more options. Riddler MFG Makes the one that i had in my xj above. It was $110 at www.jeepinoutfitters.com. you can also get a SOLID diff cover and quite a few other brands make D44 diff covers as well. Just so dome research.

The 8.25 in the Wk can use the same cover as an XJ 8.25 cover so you can get a Riddler or Solid and though there are not many other brands making 8.25 covers they are out there. also check out jeepinoutfitters.com


I also HIGHLY reccommend the use of a Lube Locker Re usable diff cover gasket. I had them both front and rear and you NEVER need to use RTV or scrape and clean the gasket surface again. not bad for about $18 a gasket.
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Old 08-14-2010, 09:07 PM
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Re: HOW TO Differential Cover

Hmm... need to see what i have. Whats an easy way to find out? Is it stamped on the stock cover?
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Old 08-15-2010, 11:50 AM
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Re: HOW TO Differential Cover

looks good in polished. Nice write up.
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Old 08-15-2010, 04:07 PM
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Re: HOW TO Differential Cover

Great write up, my powdercoated cover will be goin on within a few weeks. Can't wait to lose the rusted out one.
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Old 08-16-2010, 06:27 PM
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Re: HOW TO Differential Cover

Quote:
Originally Posted by maxst2 View Post
Hmm... need to see what i have. Whats an easy way to find out? Is it stamped on the stock cover?
Well for at least in Dana44, yes. But if you have a 4.7 i doubt you have it. Sorry
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