Original thread: http://www.ranger-forums.com/f59/how...l-cover-14184/
Let the modding Begin!!
Written by: RedPowerRanger
This is for a ford 10-bolt 8.8 aluminum rear differential cover.
1/2" socket to remove bolts
Paint scraper to remove old cover and old silicone
New differential cover with bolts
4 quarts of gear oil
Gasket maker silicone
Before you start, it might be a good idea to remove the spare tire for extra room, and clean the under area so loose dirt and particles don't fall in to the open differential.
1st. Place a collector for the oil under the diff. then, using the driver and socket, remove the bolts. The cover should stay in place.
2nd. Using the paint scraper, gently pry open the bottom of the cover to let it drain. Once the bulk of the fluid is gone, go ahead and take off the whole cover.
Make sure to let all of the old oil drain out.
3rd. Prep the mounting surfaces of the differential and the new cover by cleaning them thoroughly with a solvent. A clean surface will ensure a leak-free differential.
4th. The aluminum cover has a grove along the mounting surface for silicone.
Using the gasket maker, run a thick bead along the entire grove.
5th. Mount the new cover to the differential. Insert the bolts and tighten in a star shape, like you would mount a wheel. Do not overtighten the bolts!
6th. Refill the gear oil from the front side of the differential (next to the driveshaft on the driverside). Make sure that the fluid is even with the filler hole when on level ground.
The owners manual says 80W90 gear oil should be used. I used Royal Purple 75W90 Max Gear. If you have limited slip you should add friction modifier, the oil I used had the LS additive in it already.