Differential Cover Gasket

This procedure covers removal and replacement of the rear differential cover gasket on a 1992 Dodge Viper, including fluid drain, cover removal, gasket replacement, and refilling with proper gear oil and limited-slip additive.

Warnings

Tools required

Parts

• Differential cover gasket × 1 — Use OEM specification
• RTV silicone sealant (if gasket requires) × 1 — Permatex Ultra Grey or equivalent

Fluids

• 75W-90 GL-5 with limited-slip additive — 3.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake.
2. Place wheel chocks in front of front wheels.
3. Raise rear of vehicle using floor jack at rear differential housing or designated rear jacking points.
4. Support vehicle securely on jack stands placed under rear axle tubes or frame rails.
5. Verify vehicle is stable before working underneath.
6. Position drain pan underneath rear differential cover.

Procedure

1. 1

   Drain differential fluid
   Locate the differential cover on the rear of the differential housing. Using a 13mm socket, loosen the lower differential cover bolts first (approximately 2-3 turns) to allow fluid to begin draining into the drain pan. Work slowly to control fluid flow. Once fluid flow slows, proceed to remove all cover bolts.
2. 2

   Remove differential cover bolts
   Remove all differential cover bolts in a crisscross pattern. Verify the exact bolt count and socket size for the 1992 Viper Dana 44 cover against factory documentation before proceeding. Keep bolts organized for reinstallation. Note the condition of the bolts - they should be reusable unless corroded or damaged.
3. 3

   Remove differential cover
   Once all bolts are removed, carefully pry the differential cover away from the housing using a plastic scraper or by gently tapping with a rubber mallet. The cover may be sealed tightly with old gasket material. Allow any remaining fluid to drain completely into the pan. Remove the cover and old gasket material.
   ⚠Do not use metal pry bars between the cover and housing as this can damage the sealing surfaces.
4. 4

   Clean differential housing sealing surface
   Using a plastic gasket scraper, carefully remove all old gasket material from the differential housing sealing surface. Take care not to gouge or scratch the machined aluminum surface. Use a wire brush to clean stubborn residue, then wipe the surface clean with brake cleaner and a lint-free rag. Inspect the sealing surface for damage, warping, or deep scratches that could cause leaks.
   ⚠Do not allow debris or gasket material to fall into the differential housing. Cover the opening with a clean rag if needed during cleaning.
5. 5

   Clean differential cover
   Remove all old gasket material from the differential cover using the same process. Clean the inside of the cover thoroughly, including any magnetic drain plug if equipped. Inspect the cover for cracks, warping, or damage. The cover should be flat with no bends or distortion.
6. 6

   Inspect differential internals
   With the cover removed, visually inspect the ring gear and pinion gear teeth for abnormal wear, scoring, or metal debris. Check for excessive metal particles on the magnetic drain plug (if equipped). A light metallic coating is normal, but large chunks or excessive buildup indicates internal wear. If significant damage is observed, further diagnosis is required before reassembly.
7. 7

   Install new gasket
   Position the new differential cover gasket on the cover, aligning all bolt holes. Some gaskets may require a thin bead of RTV silicone sealant on both sides for proper sealing - consult the gasket manufacturer's instructions. If using RTV, apply a continuous 2-3mm bead around the perimeter, circling each bolt hole. Allow RTV to tack up for 5-10 minutes if specified.
8. 8

   Install differential cover
   Carefully position the differential cover with new gasket onto the housing, aligning all bolt holes. Start all 10 bolts by hand to ensure proper alignment before tightening any. Once all bolts are started, tighten them in a crisscross pattern to ensure even gasket compression.
9. 9

   Torque differential cover bolts
   Using a torque wrench, tighten all differential cover bolts in a crisscross pattern to the factory-specified torque (verify against Viper service documentation; Dana 44 covers are typically approximately 30-35 ft-lbs). Make multiple passes, gradually increasing torque with each pass (approximately 50%, 75%, then 100% of final torque) to ensure even gasket compression and prevent leaks.
   ⚠Do not overtighten bolts as this can distort the cover or crack the housing. Use a calibrated torque wrench.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
10. 10

    Refill differential with gear oil
    Locate the differential fill plug on the front or side of the differential housing (typically at the upper portion). Remove the fill plug (verify plug size/type against factory documentation). Using a fluid pump or funnel with hose, fill the differential with 75W-90 GL-5 gear oil to the correct capacity (Dana 44 is typically approximately 2.0-2.5 quarts; verify exact capacity for the Viper). If the differential is a confirmed limited-slip unit, add the limited-slip additive as specified by the fluid manufacturer. Fill until fluid reaches the bottom of the fill plug hole. Reinstall and tighten the fill plug.
11. 11

    Lower vehicle and verify
    Remove jack stands and carefully lower the vehicle to the ground. Wipe the differential cover area clean with a rag. Start the vehicle and allow it to idle briefly, then shift through all gears (if manual transmission). Turn the vehicle off and inspect the differential cover for any signs of leakage around the gasket. Re-torque cover bolts if any seepage is observed.

Reassembly

1. If RTV sealant was used, allow 24 hours of cure time before driving the vehicle hard or at high speeds.
2. Dispose of used gear oil properly at a recycling center or parts store that accepts used fluids.

Verification

• Check differential cover gasket area for leaks immediately after installation and again after a short test drive.
• Verify differential fluid level at the fill plug after the vehicle has sat level for a few minutes - fluid should be at the bottom of the fill hole.
• Listen for abnormal differential noise during a test drive - whining or growling may indicate low fluid level or internal damage.
• Re-inspect the differential cover for leaks after 50-100 miles of driving.

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