Well the rear was easy. I did notice that the gears were filthy. I used some brake cleaner, elbow grease and a lot of rags but it came out nice. Another tip is to use an old, but clean, toothbrush to clean of the crud from the gasket and around it's grooves. I wanted to make sure I had a good seal so I didn't wake up to a puddle tomorrow morning. Now for the front tomorrow before the game. Have any of you guys changed out the front diff with a PML? It seams a little tight especially for the re-torque of the flang bolts. Just got to go out and pick up a 10mm and a 17mm hex head tonight so I can change out the tranny and x-fer case tomorrow after the front diff. Hopefully Sears carries those sizes.

P.S. Thanks Mark for the QUICK delivery

 

did you reuse the stock gasket?

 

Yeah. It was too easy. Now I finished the front today. What a PITA!!! How does anyone really use a torque wrench for the top four flange bolts??? I had to use a 6mm allen wrench on the top bolts to install the PML diff cover. I torqued everything up to spec except the top bolt. I had to "feel" them out. Not enough room up there. Even if I was going to re-install the factory AAM diff cover for the front, there was no way I could figure how to use a torque wrench. I tried extensions, u-joints, adapters, etc... but nothing worked except a short and long 6mm allen wrench. The factory gasket is a thick/tough reusable rubber one. I cleaned it up real good so I would get a good seal. I had a little seepage from the rear drain bolt this afternoon but I figured it just needed to be re-torqued after running it today. I didn't use any loctite or RTV. Just the factory gasket. After thinking about it, the fact I don't have to take the cover off any more to service, maybe I should of used some loctite on the flange bolts. This would have prevented me from having to re-torque them today and possibly in the future. I don't know. I didn't want to gung up the holes in the pumpkin where the bolts go with loctite but now I'm weary about seepage. I'm use to using Permatex and not a reusable gasket like we have. I guess we'll see.

Any of you guys with a PML diff cover use or have to use Loctite or Permatex to prevent leakage?
Is the standard just to use the factory gasket and nothing else?
What about the drain and fill plugs? Did you use loctite?

 

I did not use loctite and I had plenty of room to get the torque wrench in there (2004.5 4X4, DRW) I did notice the stock flange bolts had thread sealant on them.....I did not use it. The only problem I have is seepage around the transmission pan drain bolt. I may have to try thread sealant there. If that don't work, I may have to call PML for technical advise.....maybe a new bolt and copper gasket......maybe a new pan. I sure like the way the diff. cover and trans pan look and fit though.....very good product in my opinion.

I don't think you will have a problem with leaking around your flange bolts......recheck the torqe after a few days of driving. The reusable gasket is very nice and IMHO, better than using RTV

 

Neil, are you talking about the front diff? I have a 3500 dually and the rear was easy and very open but darn, that front diff cover was a hand banger. My hands are all bashed up and skinned. I checked today and so far so good. I did notice the thread sealant to but opted against it. Kind of wish now I used some just to be safe.

 

On the PML diff covers are the fill holes at the same level as the AAM covers? I'm guessing they are so that the level stays the same.

Pete

 

Yes, the fill hole is at the same level as the stock cover.

MikeyB

 

The rear took 5 quarts and the front 3. I think I may be able to get alittle more in the front though. I did it on my driveway and it has a slight incline up to the house.

 

Junior,

Sorry....I am referring to the rear differential. I was thinking of installing one on the front, but after heraring your tale of what a PITA it is, and giving mine a close up look, I may just opt not to do it.

 

The front cover is easier to get to if you jack up the front of the truck on the frame so the suspension can hang down to get the tie rods out of the way!

 

Original Junior,

Hey no problem that's what we do at DPPI, enjoy them.

Mark @ DPPI