Instructions
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This is a pic of all the things you will get with your new SOLID differential cover (Dana 44 cover shown). Make sure that you have everything in the list before you begin this project. |
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| 1. Using the square head of a 3/8" Drive ratchet, remove the fill bolt from your Jeep JK Wrangler’s differential cover. |
2. Place an oil catch pan underneath your Jeep JK Wrangler’s differential. Then, using a 3/8" drive ratchet with a 3" extension attached to it, remove the drain bolt from the base of it as shown in this pic. |
3. Allow your Jeep JK Wrangler’s differential to drain completely before proceeding. |
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4. Your Jeep JK Wrangler’s drain bolt is magnetic and the inside end of it should be fuzzy with fine iron filings. Use a paper towel and some brake cleaner to wipe the bolt clean. |
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| 5. Using a 13mm socket, remove all 10 bolts on your Jeep JK Wrangler’s differential cover. Keep one bolt for now but the rest can be discarded as they will be replaced. |
6. Take the bolt you kept and loosely reinstall it in the top hole of your Jeep JK Wrangler’s differential cover as shown in this pic. This will keep the cover from falling during the next step. |
7. Using a dead blow hammer, strike the side of your Jeep JK Wrangler’s differential cover until it separates from the housing as shown in this pic. Remove remaining bolt. |
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8. Using a gasket scraper, thoroughly clean off the remaining RTV gasket material still attached to the mating surface of your Jeep JK Wrangler’s front differential housing as shown. Be mindful to not damage the mating surface and try not to let the removed gasket material fall inside the differential. |
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| 9. Using brake cleaner, thoroughly spray down the entire inside of your Jeep JK Wrangler’s differential. |
10. Using brake cleaner, thoroughly spray the inside of your new SOLID differential cover as well as the mating surface and wipe it clean with a paper towel. |
11. Using the tube of RTV provided with your new SOLID differential cover, draw a continuous 1/4" bead along the entire mating surface as shown in this pic. |
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12. Carefully place your new SOLID differential cover onto your differential housing making sure not to move it around too much. Then, fasten it in place using the new bolts provided with the cover. Make sure to bolt them on in a criss-cross star like pattern and then tighten them to 25-30 ft. lbs. of torque using a 1/4" allen bit. It is very important that you do NOT over torque these bolts and that installation of the cover should be done within 5 minutes after applying the RTV. |
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| 13. Using a 3/8" drive ratchet with a 3" extension attached to it, reinstall your Jeep JK Wrangler’s drain bolt back on to the base of your front differential as shown in this pic. Tighten this bolt to 25 ft. lbs. of torque. |
14. Fill up your Jeep JK Wrangler’s front differential with 2 quarts of SAE 75W-90 synthetic gear oil. DO NOT be tempted to fill up your differential with anymore gear oil or else it will get pumped out of the breather tube and make a big stinking mess. |
15. Using an H-14 hex bit, install the new fill bolt provided with the SOLID differential cover. Tighten this bolt to 25 ft. lbs. of torque. |
That’s it! Not only will your Jeep JK Wrangler’s differentials have a cool mean look to them, they will also be seriously protected from the rocks as well!
Please let me know if you have any questions and don’t forget to take your old gear oil to your local recycling center (PepBoys, Autozone or the like).
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[…] wayoflife wrote a fantastic post today on “Jeep JK Wrangler SOLID Differential Cover Installation”Here’s ONLY a quick extractIf you’re looking for a way to armor up your Jeep JK Wrangler’s front and/or rear differentials, look no further than SOLID Axle Industries. Designed as a heavy duty replacement, the SOLID differential cover is extremely well built, … […]
I just changed my diff covers out and called two dealers to make shure I got the correct fluid capacities for both 44 diffs on a 2007 Rubicon. The Front takes 2.7 pints=1.35 quarts and the rear takes 4.75 pints=2.375 quarts.
I do not know if the front diff in this write up has the
e-lokcker, or not, and maybe it does take 2 full quarts…But when I changed my front cover it looked EXACTLY like the diff in the pictures here.
Over filling can cause the seals to blow out sometimes and cause worse lubricating of bearings and gears because of airation/foaming of the oil.
Is it simply a matter of preference to use RTV?
Or is something such as the LubeLocker just as good?
Great Writeup!!!
These comprehensive wirteups take a lot of the guesswork and mystery out of seemingly daunting tasks.
Thanks WayOfLife!!!!
Paul,
I agree that over-filling your diff can be a problem but in my experience, only to the extent that it’ll make a stinking mess as your gear oil pumps out of the breather tube. Above and beyond that, I have never heard of any seals blowing or bearing damage being caused by it. Either way, I guess I should clairify that approximately 4-bottles for both axles is what you want to fill your diffs up to - the fronts will need slightly less and the rear slightly more.
Rob,
I have used RTV for as long as I can remember and have always had great no-leak results with it. While I’m sure that the Lubelocker works great, I just haven’t seen the need to use it.
Eddie
“tighten them to 25-30 ft. lbs. of torque using a 1/4″ allen bit.”
I understand how to apply the indicated torque with a torque wrench, but it appears that you are using just a ratchet. How do you ensure the proper torque? Sorry if this has an obvious answer–it’s all new to me. Thanks, and superb job on the various write-ups!
I just used a ratchet to get them on and then came back with a torque wrench afterwards. Either way, pretty tight by hand and a simple ratchet will get you to 25-30 ft. lbs.
Eddie
What are the issues associated with repeated water crossings on the diff oils?
Depends on how deep the water is and if you have any openings that might allow water to get in. So long as everything is sealed up good (no leaks), you should be fine. Other wise, a quick visual check of the fluid should tell you if it’s been compromised with water (looks like milk).
Eddie
[…] Thorough Fluid Change Instructions In order to perform a thorough differential fluid change, you will need to pull your differential covers off of your Jeep JK Wrangler’s axles. For instructions on how to do this, click on the Jeep JK Wrangler SOLID Differential Cover Installation link below as it will cover all the steps you need to follow in order to do this. Of course, if you do not have aftermarket differential covers, all you need to do is follow this write-up with the only difference being that you will be reinstalling your factory covers: […]
Eddie-
Where did you get your H14 hex bit? I’ve gone to Sears and Pep Boys and can’t find anything that large. The largest that I’ve seen in only 10mm.
thanks
Frank
Also, I’ve read some recent posts about problems with the rear trackbar rubbing the Solid dif cover. I’m running a teraflex 2.5″ BB. Do you think that I will have rubbing isssues?
Frank, I got mine as part of a set from Autozone.
Regarding SOLID diff covers, I am running one now and do not have any problems in the rear with rubbing but I do have a Full Traction track bar. I’m not 100% sure if it will make contact with a factory one.
Eddie
Did everyone else have axles that were over-filled by the factory? When I removed the fill plug on my stock cover lube poured out. I never had a problem with lube venting out the tube with the over-filled axles. I am worried about my new levels because I filled them to the right (Front 1.35 qt or 1278 ml) & (2.375 qt or 2247 ml) amounts which is less than what the factory put in. Any suggestions?