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Unread 09-16-2013, 09:28 AM   #1
AIRBORNE
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Rear diff question

I'm sorry if this is an old question. I have been going over the entire WJ, and all fluids look really good EXCEPT the rear end. It was darker than the front diff (noticeably) so I want to swap it out. Any tips on the process (special tricks or steps) or suggestion of what fluid to put in would be appreciated. Also, is that little rubber stopper something that seems to be problematic about seeping (leaking)? Just curious if it's something to replace and keep the old one for spare.

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Unread 09-16-2013, 10:31 AM   #2
Ravie
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It is a more complete process to take the pumpkin off so you can wipe out the cover and clean of the metal from the magnet. As far as sealant goes...someone else may have a better suggestion, I used RTV and I'm not sure it did so great.

Yes, those covers get harder over the years and replacing it wouldn't be a bad idea. Mine seeps all the time...
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Unread 09-16-2013, 11:27 AM   #3
MattJeep
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Definitely take the cover off to clean. Get a couple cans of brake cleaner and blast the **** out of everything. The whole inside including ring and pinion should be nice and clean. Then get a new diff gasket, should be dana 35 if you have a rubber plug. Then refill. Think 75-90 for a 35.
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Unread 09-16-2013, 11:32 AM   #4
AIRBORNE
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Do they make covers with a threaded peep filler hole?
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Unread 09-16-2013, 11:37 AM   #5
MattJeep
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Dunno. I think so. Type "dana 35 cover" on ebay.
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Unread 09-16-2013, 12:01 PM   #6
85IrocZ-28
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Quote:
Originally Posted by MattJeep View Post
Definitely take the cover off to clean. Get a couple cans of brake cleaner and blast the **** out of everything. The whole inside including ring and pinion should be nice and clean. Then get a new diff gasket, should be dana 35 if you have a rubber plug. Then refill. Think 75-90 for a 35.
D44 HD also has a rubber plug.

If the diff is a perfect oval, it is a D35.

if it is larger on the ring side (not a perfect oval), you have the D44HD.

The rubber plug could be the same though.
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Unread 09-16-2013, 06:10 PM   #7
MattJeep
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Ha, ya I just noticed that today. Thanks for correction.
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Unread 09-16-2013, 06:41 PM   #8
2004DUB
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As far as fluid I went with lucas 75w140 synthetic when I changed my front and rear in my 04 with d30/d35 and it quieted down my rear bearing noise and slowed a front left axle seal leak a good bit. I just pull the covers clean them out well with brake clean blow it out with a air gun, clean the gasket material off and throw black rtv back on.
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Unread 09-16-2013, 06:54 PM   #9
AIRBORNE
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Good advice guys. Thank you.
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Unread 09-17-2013, 04:03 AM   #10
losttech
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This place makes stock size covers with drain plugs and threaded fill holes.
http://stores.hi-potek.com/-strse-JE...Categories.bok

One of the only places I could find for the dana44a also as a fellow forum member pointed out.

I bought a set but have not had the time to install them.
Some wont like the drain plugs some will, I like them and wanted to make it easier to do the drain and fill on my diffs.
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