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How to Install Rugged Ridge Dana 44 Boulder Aluminum Differential Cover (03-18 Wrangler TJ & JK) on your Jeep Wrangler
Shop Parts in this Guide
NOTICE:
• Deep scratches and marring of sealing surfaces can cause gasket failure during installation. Take care to protect these surfaces.
• Be sure to use RTV sealant recommended for use with oil.
• It is recommended to use soft-set anti-sieze compound on threads of Drain Plug, Fill Plug, and Dipstick Bolt.
1. Drain oil if housing or current cover is equipped with a drain plug. Remove bolts from existing cover. Unattach cover from axle housing. Remove all gasket residue from axle housing sealing surface.
2. Apply RTV sealant to housing flange.
3. Install Boulder Differential Cover using supplied 5/16” Flange Bolts. Torque bolts to 30 ft-lbs using a criss-cross pattern.
4. Install Drain Plug and 1/2” Washer into bottom of Boulder Differential Cover.
5. Install Dipstick Bolt and 1/4” Washer. Fill housing with gear oil. Periodically remove and check dipstick bolt for correct capacity. This will be indicated by oil on the Dipstick Bolt in the highlighted area. Do not fill past cross hatching marks. Ensure Dipstick Bolt is reinstalled after final check of full capacity.
6. Install Fill Plug and 1/2” Washer.
