Tuesday, October 11, 2016

Step By Step Diff Cover Swap

Factory Diff Cover Replacement



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 replace factory diff covers with  tougher aftermarket cover. 


Step 1 

Gather needed tools and supplies. 

Gear Oil 👉 Buy Here

Lube Locker  👉 Buy Here


  • 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


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.



Step 3

Drain gear oil and let drain for several minutes.  



Step 4

Remove all bolts from the factory 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. 



 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. 


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"


Step 7


Clean the entire gear assembly.



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


Step 8


Attach the lube locker or apply RTV. 


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.



Step 9


Attach the new diff cover to the housing unit. 


Step 10

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



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.  


 

Step 12

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


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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