Differential Cover: Service and Repair

Differential Housing Cover













Removal

1. WARNING: If equipped with fire suppression system, refer to Fire Suppression System for Important Safety Warnings. Failure to follow this instruction may result in serious personal injury Procedures.
With the vehicle in NEUTRAL, position it on a hoist.

2. Remove the differential housing cover.

1. Remove the 10 differential housing cover bolts and drain the lubricant from the differential housing.

2. Remove the differential housing cover.
- Police vehicles have a lower axle guard.





Installation

1. NOTE: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the silicone sealant. Cover the inside of the rear axle prior to cleaning the machined surface to prevent contamination.

Clean the gasket mating surfaces.

2. NOTE: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.

Apply a continuous bead of silicone gasket and sealant to the differential housing cover.





3. NOTE: If possible, allow at least one hour before filling the axle with lubricant to allow the silicone sealant to cure.
Install the differential housing cover.

1. Position the differential housing cover. If equipped, install the axle guard.

2. Install the 10 bolts.
- Tighten the bolts in a star pattern.

- Tighten to 46 Nm (33 lb-ft).

3. Install the axle tag bolt.
- Tighten to 31 Nm (23 lb-ft).









4. NOTE: For Traction-Lok(R) axles, first fill the rear axle with 118 ml (4 oz) of additive friction modifier.

NOTE: Before attempting to remove the axle fill plug, make sure the tool recess is free of foreign material which may keep the tool from fully engaging the plug. Clean the recess with a small screwdriver or similar tool. Make sure the tool can be fully inserted into the recess before attempting to remove the plug.

NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the level shown in the illustration.

Fill the rear axle with 2.37L (5 pt) of lubricant and install the fill plug.

- Tighten to 30 Nm (22 lb-ft).





5. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury Procedures.
Repower the system.