How to Install Alloy USA HD Dana 44 Differential Cover - 3/8 in. Cast Steel (87-18 Wrangler YJ, TJ & JK) on your Jeep Wrangler

- Before beginning collect manufacturer recommended gasket maker or Dana 44 differential gasket.

- Collect factory recommended oil in correct quantity.

- Remove all parts from packaging. Ensure that you have the replacement cover, 10 cover bolts and 10 washers, and large hex filler plug wrench.

- On some vehicles such as the 2005 Jeep LJ used for this instillation you will need to raise and support the vehicle to allow the axle to drop to access all cover bolts.

1. Locate filler plug on the current differential cover and loosen with 3/8 inch drive ratchet. This is a safety precaution in case it needs to be reused.

2. Loosen and remove differential cover bolts using ½ inch socket. You may find it helpful to leave a top bolt in place to avoid dropping the cover as you remove it. The old cover may be stuck in place. If so hit it with a large hammer to break it free.

3. Drain differential oil and thoroughly clean inside differential. Oil often pools inside that you may need to scoop out.

4. Clean and dry mating surface of differential and differential cover well. Remove old sealant or gasket as needed. Inspect gears.

5. Retain differential tag from old cover. This tag contains important information about your differential. You will not be able to replace it on the new cover. Store in a safe location.

6. Apply gasket maker or gasket according to manufacturer directions to new cover and install using supplied bolts and washers. Thread all bolts in loosely by hand before tightening. Do not over tighten. The factory recommended torque values might be too high for this hardware.

7. Fill with manufacturer recommended oil.

8. Replace fill plug. Tighten with supplied 12mm hex wrench. Installation complete.

Installation Instructions Written by ExtremeTerrain Customer Jason Horn 10/30/2017.