Bomb Proof Dana Model 30 & 44 Differential Cover Install

It's been a long time coming but I have found the time and tools this weekend to complete a differential lube change and INSTALL AtoZ Fabrications Bomb Proof Dana 30 & 44 Differential Covers.

Unlike any other differential cover, these things are extremely well built, super beefy, affordable, have a machined mating surface for a flat fit, and look fantastic unlike their competition.

Need I say, when you're ready to provide maximum protection for your Dana 30 front or Dana 44 rear differential, look no further than AtoZ Fabrications! ! !  

What You will Need:

• Bomb Proof D30 & D44 Differential Covers
• 4 Quarts Synthetic SAE 80W-90 GL5
• Lube Lockers or Permatex Black RTV
• 1/2" Socket
• H-14 Hex Bit
• 3/8" Ratchet
• Torque Wrench
• Flat Chisel
• Dead-blow Hammer
• Gasket Scraper
• Brake Cleaner
• Paper Towels
• Oil Catch Pan
• Newspapers
• Wheel Chocks
• Bottle Pump

Check out the following pictures of the before and after shots of how the axle will look. Also, pay close attention to the comparison photos between the stock covers and BOMB PROOF Dana Covers…..

Dana 30 Front Stock                           Dana 44 Rear Stock

                
Installation

1. Here is a picture of items you will need with your new heavy duty Dana 30 & 44 differential cover. As you can see in the 1^st photo, it comes unpainted!

2. It's a good idea to prep, prime and paint your new differential covers to the color of your choice before installing it on your Jeep. If you do not paint it, it will start to rust over time. I chose to paint mine with Rustoleum Primer and Tank Gray Paint.

3. Park your Jeep on level ground. Then, place some newspaper and an oil catch pan underneath the differential.

4. Using a 1/2" socket, remove all but the very top bolt on the differential cover. This bolt should be loose but not removed so that when the cover comes free, it does not fall into the oil catch pan.

5. Place a flat chisel between the differential and cover and then carefully tap it with a hammer until the cover separates just a bit. Carefully pry open the differential cover just enough from the bottom and let the fluid drain slowly into your oil catch pan.

6. Once drained, remove the remaining bolt holding your differential cover and carefully pry the whole thing off. Wipe up as much of the oil that remains in the differential with paper towels. Use some brake cleaner to help you clean things and then wipe everything down thoroughly.

7. Now, wrap up your differential gears in paper towels the best you can and start cleaning off all the old gasket material.

8. The differential mating surface must be completely clean to insure a proper seal. A gasket scraper works really well here and can be bought at your local auto parts store for only a few bucks. Be careful not to scratch or score the mating surface while cleaning it.

9. Thoroughly clean the inside and mating surface of your new differential cover with some brake cleaners and paper towels.

Next, test fit and align Lube Locker Gasket with your new differential cover.

OR

Apply a continuous 1/4" bead of RTV along the mating surface of the differential cover.

10. Carefully place the differential cover onto your differential making sure not to move it around too much. Fasten the differential cover in place using new bolts. I purchased my new 3/4” long Grade 8 bolts at the local Hardware Store. Make sure to bolt them on in a criss cross pattern and then tighten them to 25-30 ft. lbs. of torque. It is very important that you do NOT over torque these bolts.

Dana 30 Front Complete

11. Now, fill up your D30 front differential with 1.25 quarts and D44 rear differential with 2 quarts of SAE 80W-90 GL5 gear oil. DO NOT fill your differential with anymore oil or else you will have problems with gear oil being pumped out of the breather tube.

12. Using an H-14 hex bit, install the new fill bolt provided with the differential cover. Tighten this bolt to 25 ft. lbs. of torque.

13. That's it! This is what everything will look like when all is said and done. Not only will your axle look great now, your differential will be seriously protected from the rocks too!

Dana 44 Rear Complete

14. Please let me know if you have any questions and don't forget to take your old gear oil to your local recycling center (Pep Boys, AutoZone or the like).