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.
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.