Originally Posted By: Trav
It doesn't take much oil to screw the seal of the the RTV. Napa sometimes has a gasket or i buy the heavy gasket material and make my own.
It only takes a few min and guarantees no leaks.
IT is not the fluid that causes leaks, but usually the methodology and the materials used.
I agree, cleanliness and removal of the oil film on the surfaces is paramount.
Here is the procedure I have used over the years with zero leaks and always using synthetic lubes. Below is Mola's 12 point plan:
1.
Unscrew fill bolt and place oil pan under diffy. Remove lower cover bolts from 2:00 O'clock to 10:00 O'clock positions.
2. Back out remaining bolts 1/2 of the way out from 10:00 O'clock to the 1:00 O'clock position.
3. Using sharp and broad screwdriver, gently wedge point into 6:00 O'clock position between differential cover and differential case to separate bottom part of cover from diffy case. Do not scratch differential case mating surface. Have patience.
4. Let oil drain until only drops appear.
5. Remove remaining bolts and remove cover. Clean bolts in volatile solvent and dry.
6. Use paper towels or discardable cotton rags to rake out remaining oil pooled in bottom of diffy case.
7. Take scraping tool and clean gasket material and or RTV sealant from
ALL surfaces.
8. Spray all mating surfaces (cover and case) with brake fluid cleaner and wipe dry until all surfaces have no oily film.
9. Using paper gasket, coat paper gasket with a thin film of Permatex "Ultra Black" (PX #82180) using thumb and middle finger to evenly apply the thin coat. Wipe excess.
10. Position and press gasket on diffy cover using half the bolts from the diffy cover to align coated gasket.
11. Let sit for two minutes, then apply cover to diffy case and tighten bolts to spec.
12. Two hours later, add differential lubricant.
