I'm going to open my rear differential (Dana 35 open diff), and since this is the first time i'm doing this i need some tips. I already asked a few questions on the "Ask the Question" thread.

I'm using Valvoline API GL5 75w90, and Blue RTV to make the gasket. Sound good? I need to know about how much fluid the diff will take (So i know if i need to buy one or two 1-quart bottles)

While I'm in there, I'm going to inspect for damage (Diff was submerged in water, and i don't think the fluid was replaced). Also can i clean it with brake cleaner?

 

I believe it will take about 2-2.5 quarts of oil. i have the sheet that says the amount out in the jeep. i usually use a red or black high temp rtv. you can use brake cleaner to clean it all out. just spray everything in there till clean.

 

Well good news to the guys who helped me in the question thread, i remembered the color wrong lol. It's golden, and actually does look like it was replaced recently.... I might have to look back at past service receipts.

Gonna replace it anyways though, just to be safe.

 

It super easy man, don’t sike yourself out.

When draining, loosen all the bolts around the pumpkin. Just because they are loose doesn’t mean it will start to drain, the RTV sealant on there will hold the cover in place. Remove all the bolts except for the TOP CENTER bolt, this will hold the cover in place and allow you to control the flow of the gear oil as it drains out, otherwise it will all come out at once and make a big mess. Pry a screwdriver between your cover and axel to realase the sealant.

Clean it all up however you like, slap some paint on er’ and apply your sealant around each bolt hole and the perimeter of the diff case. (kinda in a continues fashion, nice 1/4" bead)

Put your cover back on, tighten your bolts and let sit for …. 30 – 60 mins (not too sure exactly how long) before putting oil back in your case. Use a bendy funnel to get the oil in, you can’t overfill the case because of the horizontal filler hole, the excess oil will just leak out.

Bada-bing. you done.

 

make sure you rtv around the bolt holes complete circle.

 

I like to use the gallon jug of gear oil with a pump. It's much easier to get the oil in and I will have oil left over for topping off later if need be.

 

Save yourself some headaches.. get some of this stuff--->
* Gear Oil RTV Sealant by Permatex (part#81182)

 

Roger!