M
mojowrangler
Guest
Original poster
This is my first post on this website after purchasing a 1997 Jeep Wrangler Sport (4.0L 6 cylinder, 32RH). I'm posting this as a sanity check - in case anyone has run across this and has advice, or as a cautionary tale for others.
I was told from the previous owner that the dana 44 (geared 4.1) front and rear axels came off an 04 Wrangler Rubicon (which also has electronic lockers front and rear controlled by two rocker switches).
I'm going through all the fluid changes now and got to the differentials today, I drained less than 3 quarts total out of both differentials (less than 1.5 quarts each). I didn't measure exactly, but the total drained fluids (from front and rear) fit into 3 quart size containers. I assumed that I should fill to the upper fill plug (as is common with similar things I've done in the past), but discovered that the differential capacity was significantly greater than the oil I removed. Doing a little research, the differential covers were both replaced with G2 aftermarket covers (part number 40-2033AL). I believe the fill hole placement allows overfilling the differentials, which I did (not paying attention or having enough experience with this).
I now plan to drain the differentials again and fill to the recommended levels. I'm having trouble finding an authoritative reference on how much gear oil (or what kind) to use, but I've seen some references to 1.3 quarts each. I'm hoping to verify this before I start over. I also plan to use Valvoline 80W-90 unless I find more specific recommendations.
As a side note, the drain plugs and fill plugs appeared to be reversed when I pulled them off. The plugs with the magnets were used as the fill plugs and the plugs without magnets were used as the drain plugs. I assume there's no reason to set it up this way so I reinstalled with the magnets on the drain plug side. I also looked up the specs for torque setting and found something that said 25 to 30 ft lbs, so I set my torque wrench to 27, but this seems high. I now realize the aftermarket aluminum cover probably has a different spec, but I'm having trouble finding this.
I posted pics of the valve covers, which shows the fill plug positions. My understanding is that the OEM covers did not have drain plugs. Therefore the covers would need to be removed to drain the gear oil.
Again, this is all just a sanity check. If it sounds like I'm off base with any of this, I'd appreciate the feedback. I did search through the forums before I posted this but I didn't find exactly what I was looking for on the '04 dana 44 recommended levels (with lockers) or mention of these aftermarket G2 covers on them.
I was told from the previous owner that the dana 44 (geared 4.1) front and rear axels came off an 04 Wrangler Rubicon (which also has electronic lockers front and rear controlled by two rocker switches).
I'm going through all the fluid changes now and got to the differentials today, I drained less than 3 quarts total out of both differentials (less than 1.5 quarts each). I didn't measure exactly, but the total drained fluids (from front and rear) fit into 3 quart size containers. I assumed that I should fill to the upper fill plug (as is common with similar things I've done in the past), but discovered that the differential capacity was significantly greater than the oil I removed. Doing a little research, the differential covers were both replaced with G2 aftermarket covers (part number 40-2033AL). I believe the fill hole placement allows overfilling the differentials, which I did (not paying attention or having enough experience with this).
I now plan to drain the differentials again and fill to the recommended levels. I'm having trouble finding an authoritative reference on how much gear oil (or what kind) to use, but I've seen some references to 1.3 quarts each. I'm hoping to verify this before I start over. I also plan to use Valvoline 80W-90 unless I find more specific recommendations.
As a side note, the drain plugs and fill plugs appeared to be reversed when I pulled them off. The plugs with the magnets were used as the fill plugs and the plugs without magnets were used as the drain plugs. I assume there's no reason to set it up this way so I reinstalled with the magnets on the drain plug side. I also looked up the specs for torque setting and found something that said 25 to 30 ft lbs, so I set my torque wrench to 27, but this seems high. I now realize the aftermarket aluminum cover probably has a different spec, but I'm having trouble finding this.
I posted pics of the valve covers, which shows the fill plug positions. My understanding is that the OEM covers did not have drain plugs. Therefore the covers would need to be removed to drain the gear oil.
Again, this is all just a sanity check. If it sounds like I'm off base with any of this, I'd appreciate the feedback. I did search through the forums before I posted this but I didn't find exactly what I was looking for on the '04 dana 44 recommended levels (with lockers) or mention of these aftermarket G2 covers on them.