How to Replace the Rear Differential Oil in a Dodge Ram 1500

Video tutorial on how to replace the rear differential fluid in a Dodge Ram. Here I’m working with a third-generation general truck, it’s a 2006 to be exact, 1500, 4×4 model, equipped with the 9.25 limited-slip 12 bolt axle. Your owner’s manual should list the types of oil required, but may not list the capacities. Maintenance intervals for the fluid is 25,000 km or 15,000 miles and the amount require specifically for this truck was 2.5L or about 2.6 quarts. With this truck being new to me, any previous maintenance was fairly unknown to me and I was having issues where the limited-slip was shuddering on some takeoffs and around slow corners. #DodgeRam

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Tools/Supplies Needed:
-oil safe sealant with applicator gun
-brake cleaner
-clean rags or shop towels
-latex/nitrile gloves
-new oil (#Amsoil) & friction modifier
-scraper
-hammer
-scuffing pad
-socket set with ratchet
-ear clamp cutter
-gear clamp
-air compressor
-oil pan

Procedure:
Have an oil pan ready and start loosening the 13mm bolts with a socket and ratchet. Once all have been broken loose, it should be easy to remove them by hand. The two top bolts are backed out about halfway so I can tilt the bottom of the cover out and drain the oil into the pan. The cover from the factory will have a sealant and this can be broken by using a scraper. It should be fairly easy to pop the seal. Once broken free, let the oil drain into the pan.

The bolts did have some sealant on them and that was cleaned up using a wire brush. Once the oil has stopped dripping, next is removing that cover. Remove the two top bolts, then pull off the cover.

Using brake cleaner, spray the inside of the differential to remove any sludgy build-up. It’s best to remove as much as possible of the old oil as it’ll just contaminate the new oil. There is also a magnetic at the bottom, make sure all the debris is removed from that and it’s clean as well. I used a shop towel to remove any pooling of fluid at the bottom.

To remove the old sealant, a scraper can be used. Do not cause nicks or deep scratches on the sealing surface. A razor blade can work as well. Using a scuffing pad, this will remove any remaining material on the sealing surface. This scuffing pad is equivalent to 400 grit. Make sure all the old sealant is removed. Do the same for the cover too.

I degreased the cover to remove any old oil reside and finished up on the sealing surface with the scuffing pad. The sealing surface is cleaned up with a solvent to remove any dirt or oil residue which may cause issues for the adhesion of the sealant. Do the same on the axle, cleaning the sealing surface, removing any chance of contamination.

Use an oil safe gasket maker, apply it to the cover or axle. Be sure to consult with the product instructions for the application process. We’re looking for at least a 3mm or 1/8” bead all the way around the cover. I went around all the fastener holds and make a straight light from each hole. Once the cover is bolted into place, the bead will flatten out and there should be at least a 13mm or 1/2” seal all the way around.

Install the cover. Trying to line up the holes, then install the bolts. Install a few so the cover stays in place, then finish up with the rest. Don’t put pressure on the cover just yet so the sealant doesn’t push out and fill the threaded holes. For tightening, the bolts must be tightened in a criss-cross pattern to prevent the cover from deforming where it may cause sealing issues. The torque specifications for these bolts are 30 ft-lbs or 40 nm.

Differentials do have a vent to equalize pressure, it’s a good idea to check your vent line so it’s not plugged. This is on the axle tube on the driver’s side and has a single ear clamp. Sealants do have different dry times, refer to the product’s instructions.

Remove the plug, make sure you do have the drain pan under the fill location to catch any dripping fluid. Being that this is a limited-slip, a friction modifier is required for the clutches. Some oils already have this addictive, this oil I am using does, however after a quick trip up the road, I did notice a little chatter. Clean off any oil reside and check for leak.

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