Tuesday, October 11, 2016

Step By Step Diff Cover Swap

Factory Diff Cover Replacement

Working on my Diffs

Finally, I got the courage to swap my diff covers. Doing this install all by myself was a huge boost to my confidence. The most difficult part was taking my own pictures and videos while swapping out my stock Diff Covers for new covers. 

Step By Step Guide to Diff Cover Swap 👉 Watch Here

Step By Step Guide to replace factory diff covers with  tougher aftermarket cover. 

Step 1 

Gather needed tools and supplies. 

Gear Oil 👉 Buy Here

Lube Locker  👉 Buy Here

Tools for gear oil change

  • Drain Pan
  • Riddler Manufacturing Diff Cover & hardware
  • Ratchet
  • 3" Ratchet Extension
  • #9 Allen Wrench
  • Flat head Screwdriver
  • Mallet
  • Razor Blade Scraper
  • White rags
  • 2.5 Quarts 80W90 Gear Oil
  • Brake Parts Cleaner
  • Empty gallon water bottle
  • Mechanix gloves
  • Plastic gloves

Step 2

Remove the lowest drain plug

Diff drain hole

I used the 3" Ratchet extension for this. I was not ready for the horrible smell once the oil came oozing out. Nor was I quick enough to get the drain pan under the draining diff. I got a little dirty. Next time I will not use something so deep. Then I will be able to keep the drain pan in position while I removed the plug.

Gear Oil spill

Step 3

Drain gear oil and let drain for several minutes.  

bucket of stinky gear oil 

Step 4

Remove all bolts from the factory diff cover. 
removing bolts from diff cover

removing bolts from diff cover 

I was worried about this part. I usually have a difficult time loosening bolts but with my Mechanix gloves, and a lot of determination, I did it! It took longer than most, but I persevered. 

Mechanix Gloves 👉 Buy Here

Step 5

Pry the cover off the housing unit. 

prying diff cover off

 I used a flat head screwdriver and a mallet to get mine off. Luckily for me there was some small gouges from the rocks. This allowed me to get the screwdriver in between the stock diff cover and housing unit.

Step 6

Completely remove the old gasket on the housing. 

Removing old gasket

This is critical for a good seal when putting on the new Diff Cover. It was the most time consuming of all the steps. I wanted to make sure I removed every bit of the old gasket "goop"

Removing old gasket with razor blade

Step 7

Clean the entire gear assembly.

Diff empty of oil

I used a brakes parts cleaner. I also had to put on a face mask as this stuff is potent. I did this in shifts as the fumes got to be too much.  

Brake Cleaner 👉 Buy Here

Close up of gears in diff

Step 8

Attach the lube locker or apply RTV. 

Lube Locker 

Line up the lube locker onto the diff cover. Then carefully get it ready for Step 9. This was a little difficult trying to do without another person.

Lube locker lined up on diff

Step 9

Attach the new diff cover to the housing unit. 

Aligning diff cover 

Step 10

Hand thread the bolts according to the Lube Locker instructions. It is a star pattern. 

Directions to tighten bolts on diff cover 

Step 11

Tighten the bolts evenly by alternating to assure the plate is mounted evenly with the same pressure making sure each bolt becomes tight but not super tight.  

New purple diff cover

Step 12

Put the drain plug back in using a number 9 Allen Wrench. 
diff drain plug 

Step 13

Fill with 2.5 quarts of 80W90 gear oil. 

Disclaimer: Any advise and information provided on this blog should be verified by professional sources prior to making any changes or modifications to your vehicle. 

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