Differential Cover: Service and Repair

Differential Housing Cover





Material

Removal





1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the LH side of the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

Raise and support the vehicle.





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

Installation

1. CAUTION: 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. CAUTION: 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 clear silicone rubber to the differential housing cover.





3. NOTE: If possible, allow 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.
2 Install the bolts.





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

CAUTION: 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 1.8 liters (3.75 pints) of lubricant and install the fill plug.





5. NOTE: If equipped with air suspension, reactivate the system.

Lower the vehicle.