Differential Cover Gasket

Replace the rear differential cover gasket on a 2014 Ram 2500 4WD with 6.7L Cummins to repair leaks and restore proper sealing.

Warnings

Tools required

Parts

• Rear differential cover gasket × 1 — Use OEM Mopar gasket or equivalent
• RTV silicone sealant (optional backup) × 1 — Mopar RTV or equivalent

Fluids

• Mopar 75W-140 Synthetic Gear Lubricant — 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 driven
4. Raise rear of vehicle and support securely on jack stands rated for vehicle weight
5. Position drain pan beneath rear differential cover

Procedure

1. 1

   Remove differential cover bolts
   Locate the rear differential cover on the rear axle housing. Using a socket wrench, loosen all differential cover bolts in a criss-cross pattern. Remove all bolts except the top two, leaving them slightly threaded to prevent the cover from falling.
2. 2

   Drain differential fluid
   With drain pan positioned properly, carefully pry the bottom edge of the differential cover away from the housing using a flathead screwdriver or pry bar. Allow gear oil to drain completely into the drain pan. Once drained, remove the final two bolts and remove the cover completely.
3. 3

   Clean differential cover and housing mating surface
   Use a gasket scraper or plastic scraper to thoroughly remove all old gasket material from both the differential cover and the housing mating surface. Follow up with a wire brush to remove stubborn residue. Clean both surfaces with brake cleaner and wipe dry with clean rags. Ensure no debris falls into the differential housing.
4. 4

   Inspect differential internals
   With the cover removed, visually inspect the ring and pinion gears for excessive wear, chips, or damage. Check for metal shavings in the old fluid (small amounts are normal). If significant damage is observed, further repair may be necessary before reinstalling cover.
5. 5

   Install new gasket and position cover
   Place the new differential cover gasket onto the cover, aligning all bolt holes. If desired, apply a thin bead of RTV silicone to the gasket for additional sealing. Position the cover with gasket onto the differential housing, ensuring proper alignment of all bolt holes.
6. 6

   Install and torque cover bolts
   Install all differential cover bolts finger-tight. Using a criss-cross pattern starting from the center and working outward, tighten bolts gradually in multiple passes. Final torque all bolts to specification using a torque wrench in the same criss-cross pattern to ensure even gasket compression.
   Torque spec

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

   Refill differential with gear oil
   Locate the differential fill plug on the front of the differential housing (typically at mid-height). Remove the fill plug. Using a fluid pump or funnel with extension hose, add Mopar 75W-140 Synthetic Gear Lubricant until fluid begins to drip from the fill hole. Install fill plug and tighten securely.
8. 8

   Lower vehicle and verify repair
   Lower the vehicle from jack stands to the ground. Wipe down the differential cover area with a clean rag. Start the vehicle and allow it to idle for 2-3 minutes. Shift through drive and reverse several times to circulate fluid. Shut off engine and inspect cover for any signs of leakage.

Reassembly

1. Ensure all differential cover bolts are torqued to specification in proper sequence
2. Verify differential fill plug is installed and tightened
3. Double-check that no tools or rags were left in the work area

Verification

• Inspect differential cover gasket area for any signs of fluid seepage immediately after service
• Drive vehicle 10-20 miles and re-inspect cover area for leaks
• Check differential fluid level after first drive cycle to ensure proper fill
• Monitor for leaks over the next few days of normal driving

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