Replace the rear differential cover gasket to repair leaks, including draining and refilling with fresh 75W-90 GL-5 gear oil.

Warnings

Tools required

Parts

• Rear differential cover gasket × 1 — Use OEM specification
• Rear differential drain plug washer (if equipped) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks in front of front wheels
3. Allow differential to cool if vehicle was recently operated
4. Raise rear of vehicle with floor jack and support securely on jack stands at manufacturer-specified lift points
5. Remove rear wheels to improve access (optional but recommended)
6. Locate rear differential cover on underside of vehicle - it is the flat metal cover on the rear of the differential housing

Procedure

1. 1

   Drain rear differential fluid
   Position drain pan directly beneath the differential cover. Slowly loosen the differential cover bolts in a crisscross pattern, leaving the top two bolts partially threaded. Allow fluid to begin draining from the bottom edge. Once draining slows, remove the remaining bolts and carefully lower the cover, allowing remaining fluid to drain completely into the pan. Keep cover oriented to prevent spilling trapped fluid.
2. 2

   Remove differential cover and old gasket
   Once fluid has fully drained, remove the differential cover completely. Remove and discard the old gasket from both the cover and the differential housing mating surface. If gasket material is stuck, carefully use a plastic scraper to remove it without gouging the metal surfaces.
3. 3

   Clean mating surfaces
   Thoroughly clean both the differential housing flange and the cover mating surface using brake cleaner and clean rags. Remove all old gasket material, oil residue, and debris. Use a wire brush if necessary for stubborn deposits. Ensure surfaces are completely clean and dry before proceeding. Inspect the magnetic drain plug (if present on cover) and clean off any metal particles.
4. 4

   Inspect differential interior
   With the cover removed, visually inspect the differential gears for obvious damage, excessive wear, or metal debris. Check for broken teeth or scoring. If significant metal particles were on the drain plug or excessive wear is visible, further inspection by a professional may be required.
5. 5

   Install new gasket and position cover
   Position the new gasket onto the differential cover, aligning all bolt holes. Some gaskets may have adhesive backing; others may require a light coating of gear oil to hold in place. Carefully lift the cover with gasket into position against the differential housing, ensuring the gasket remains properly aligned and does not shift.
6. 6

   Install and torque differential cover bolts
   Thread all differential cover bolts by hand to ensure proper alignment. Tighten bolts in a crisscross pattern in multiple stages: first snug all bolts finger-tight, then tighten to half specification, then torque to final specification. This ensures even gasket compression and prevents leaks.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
7. 7

   Fill rear differential with gear oil
   Locate the fill plug on the front or side of the differential housing (typically 10mm hex). Remove the fill plug. Using a fluid pump or funnel with extended hose, add 75W-90 GL-5 gear oil through the fill hole. Fill until oil begins to drip from the fill hole, indicating proper level (approximately 2.0 quarts). Reinstall and hand-tighten the fill plug.
8. 8

   Reinstall wheels and lower vehicle
   If wheels were removed, reinstall them and hand-tighten lug nuts. Lower vehicle carefully from jack stands to the ground. Once vehicle weight is on wheels, torque lug nuts in a star pattern to specification.
   Torque spec

   Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure differential cover bolts are torqued in proper sequence to prevent gasket distortion
2. Verify fill plug is reinstalled securely to prevent fluid loss
3. Double-check that drain pan and tools are removed from under vehicle before test drive

Verification

• Check for leaks around the differential cover gasket immediately after completion
• Test drive vehicle for 5-10 minutes, then recheck differential cover area for any signs of seepage
• After 50-100 miles of driving, inspect cover gasket area again and retorque cover bolts if necessary
• Verify proper fluid level by removing fill plug - oil should be at the bottom of fill hole threads

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