A differential cover is often overlooked when it
comes to the axles. Many people choose to ignore the fact that the
thin metal cover is not much protection between your gears and a
rock. The stock covers hold little fluid and doesn't offer any
cooling. You would be surprised how hot a differential will get
when towing or if you're running large tires. And if you happen to
be running a chrome cover, that's actually worse since the chrome
holds in heat. After going through the cost of a front Dana 60 and
rear GM 141 bolt, (14-10.5) plus the cost of the Detroit locker in
the rear and the ARB air locker in the front, we wanted a better
differential cover to protect our investment. Basically, we were
looking for something that could offer added fluid capacity,
aluminum construction for better cooling and the ability to take
any off-road abuse we may encounter. Mag-Hytec covers offered
everything we were looking for not to mention the covers came with
a magnetic drain plug and a dipstick for monitoring fluid levels.
For our needs, the Mag-Hytec diff covers provided a logical fit.
Features of Mag-Hytec covers:
Cast in thick A356T6 aluminum
Increased lubricant and cooling capacity (usually double)
Fluid runs up to 45 degrees cooler
Equipped with a magnetic drain plug
1/8 NPT temperature sender fitting
Lube reference plug (for stock level)
Magnetic dipstick for checking fluid level and condition
Dipstick, drain, and reference plugs are MS 33649 and fitted
with AS 568 O-rings
Large O-ring cover gasket, which requires no sealant or
gasket
All hardware is stainless steel (on rear covers)
Cover is texture-powdercoated in black
Cooling fins
Offers easy routine maintenance without removing the cover
Everything included for a "do it yourself" service and
installation (includes tools)
Stainless steel hardware
Lifetime Warranty
Mag-Hytec
cover come with everything you need to do the install and upkeep
including the bolts and tools. The Dana 60 cover is on the left and
the 14-10.5 cover is on the right. These covers are super thick and
are much larger than stock.
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The first thing noticeable when you take the 14-bolt cover
out of the box is the weight and depth of the unit. The mounting
flange thickness is 1/2-inch and the cover is 1/4 to 3/8-inch
thick. As well as offering increased lubricant and cooling capacity
(up to 45 degrees cooler), Mag-Hytec covers set your vehicle apart
in both aesthetics and function - cast in A356-T6 aluminum and
textured powdercoated black with machined cooling fins. Magnetic
drain plugs trap worn gear material promoting fluid integrity. Each
unit is fitted with ARP 568 O-rings for superior sealing. All
hardware is 303 stainless steel to avoid corrosion. After
installing a Dana 60 cover on the front axle, the tie rod will be
fairly close to the cover due to its size, but it should fit. Just
position the cover sideways and finagle it in between the gears and
the tie rod until it drops down into position. Under full lock
(wheels turned all the way in one direction) the tie rod is very
close to the cover but does not come in contact with it.
At full turn,
the tie rod comes close to the cover but still clears.
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Hold the chrome please Ok, we admit running the chrome
diff covers in the past. The main problem with chrome is it holds
in heat which isn't what you want for a cool axle. Heat can kill
gears so this is important to us with our new gears. Another
problem with most chrome covers is they are usually much thinner
than the stock cover. We noticed this with the chrome 14-10.5 cover
we were running previously. It wouldn't take much to dent it on the
trail. Why a Magnet? As the metallic components in
transmissions and axles wear, they generate very fine particle
debris that becomes suspended in the lubricating oil. A suspended
magnet acts as a filter to contain the particles, keeping the fluid
cleaner and extending component life. Periodic checking and
cleaning of the magnets is recommended for maximum fluid service
life. New Gears?
You just purchased a new ring & pinion and you're ready to feel
the power. Hold on! That new gear set may become scrap metal faster
than you can say "burned up oil". All new ring & pinion sets
run hot until they are "broken in" and in some situations they can
run hot enough to break down the gear oil and damage the gear set.
Some of those situations are:
Towing
Tall tires
Heavy loads
High numeric gear ratios (4.56 & up)
Motorhomes
New gears are lapped at the factory but some are lapped more than
others and even with lapping they are still not lapped under the
same pressures that driving creates. The loads generated while
driving force any microscopic high spots on the gear teeth back
into the surface of the metal. This is called "work hardening".
Work hardening is similar to forging in the way that it compresses
the metal molecules into a very compact and hard formation. This
can only be accomplished if the metal surfaces are lubricated and
the temperature is not hot enough to change the molecular structure
due to the heat alone. If the temperature of the metal gets hot
enough to change the molecular structure it will soften the surface
instead of hardening it. This may seen like a balancing act but it
all happens easily & passively as long as the oil keeps the
gear cool while it is breaking in. All new gear sets require a
break-in period to prevent damage from overheating. Usually 500
miles will break in the gears but until then, you want a cool rear
end. The greatest damage results when a new ring & pinion has
been run for several miles during the first 500 miles and the oil
is very hot. Any heavy use or overloading at this time will cause
irreparable damage to the gear set. So all this means keeping your
rear end cool. By using Mag-Hytec covers, you can be assured your
new gears will be fine. Just remember: ANY OVERLOADING OR
OVERHEATING WILL CAUSE THE GEAR OIL TO BREAK DOWN AND THE RING
& PINION WILL FAIL. Installation:
Installation is easy because the covers come with all the hardware
that you need, including the proper size allen wrenches and very
detailed instructions. We installed these covers the same time the
gears were changed which is the reason why it's on a lift. The
covers can easily be installed with the vehicle on ground. Note:
For some installations, removing the spare tire may provide better
access to the work area. However it is not necessary in every case.
The installer should determine if there is adequate workspace prior
to starting the installation.
Park your vehicle on level ground and apply the parking
brake
Position a drain pan under the differential to catch the old
gear lube.
Remove the 10 existing bolts, starting at the bottom. (14-10.5
Mag cover has 12 bolts)
Using a gasket scraper, start at the bottom of the cover and
carefully (so as not to gouge the housing metal) insert between the
existing cover and gear housing and pry the old cover off.
Allow all of the old gear lube to drain.
The wretched
smelling gear oil is drained and cover is removed.
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Using a gasket scraper, carefully remove all of the old gasket
material (dried silicone) from the housing. A wire brush may be
required to aid in cleaning the gasket surface.
The old
gasket is removed using a scraper.
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Use clean lint free rags to wipe down the remaining oil from
inside the housing and to clean the housing gasket surface. The
surface must be clean and flat for the Mag-Hytec O-ring to
seat.
Before installing the new Mag-Hytec cover, check the
gasket-mating surface on the differential housing for dents,
irregularities, or gouges. Should any exist, carefully remove the
high spots using a smooth flat file. BE CAREFUL NOT TO ROUND OFF
THE FLAT GASKET SURFACE.
Using gear lube, apply a light thin layer of oil to the
Mag-Hytec cover O-ring.
Position the cover by aligning the bolt holes and start one of
the new stainless steel allen cap screws and stainless steel
washers at the top bolt hole and continue around the bolt pattern
until all 10 bolts and washers are installed finger tight.
The cover is
placed on the Dana 60 the bolts are started.
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Using a 5/16 hex bit and 3/8 drive torque wrench, torque the
stainless allen cap screws to 25-30 ft. lbs. in a cross tight
pattern.
The screws
are tightened with the supplied allen wrench. Later the bolts are
tightened to 25-30 ft. lbs.
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Note: When installing the cover on a 14-bolt axle, the brake
line bracket that attaches to the cover via a cover bolt will have
to be modified. Simply remove the brake bracket and round the
corners off with a grinder until it fits into the cover bolt
indentation. There was another clip on the left that had be ground
also.
We ran into a
little snag where the brake line brackets didn't want to cooperate.
A little grinding action took care of that.
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Check the drain plug, oil reference plug, and 1/8 pipe plug for
tightness. If you are going to install a temperature sender, do so
at this time. Remove the 1/8 pipe plug and install the sender in
its place. BE SURE TO USE LPS ALL PURPOSE ANTI-SEIZE OR EQUAL ON
THE SENDER'S PIPE THREADS DO NOT OVER TIGHTEN!
Remove the dipstick assembly, and add in the new gear lube.
Your new cover will take approximately 4 quarts for the Dana 14
bolt and 3 quarts for the Dana 60. There are two marks on your
dipstick. The bottom mark represents the minimum fill line and the
top mark is the maximum fill line. YOUR OIL LEVEL SHOULD BE BETWEEN
THESE LINES. Note: when checking the oil level, remember to thread
the dipstick assembly until the assembly is threaded in all the
way. Remove the dipstick assembly and check the level. If the oil
level is between the two lines, apply a thin film of oil to the
dipstick assembly O-ring and reinstall. Tighten snugly (30 in.
lbs.). BE CAREFUL TO NOT OVER TIGHTEN THE ASSEMBLY.
The
differential is then filled with LE gear oil through this handy
dipstick hole.
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Note: If you have a special application vehicle, or your vehicle
has been modified or lifted and the axle has been rotated, you will
have to establish the correct oil level for your vehicle as the
dipstick marks as supplied by Mag-Hytec will not apply. The correct
oil level should be between the bottom of the inside of the axle
tube and bottom of the axle shaft. Once you have established the
correct level, scribe a reference line on your dipstick for future
reference, and fill the differential.
If you have a limited slip differential, be sure to add the
appropriate amount of friction modifier. Mag-Hytec suggests
Chrysler friction modifier, which is compatible with Amsoil
synthetic gear lubes. (ONE TO TWO 4 OZ. CONTAINERS SHOULD PROVIDE
THE DESIRED RESULTS.)
After installing the cover simply remove the magnetic dipstick and
fill with the proper fluid. We took Mag-Hytec's advice and went
with LE (Lubrication Engineers) 607 Almasol, SAE 90 / ISO VG 220 to
protect the differential gears and new locker. After dumping 5
quarts into the rear of the Blazer I took it for a test drive
around the block and drove it back into the garage for a final
inspection, no leaks and no problems at all. The cover adds an
aggressive look to the Blazer, makes it easy to check and change
the gear oil and offers the ability to check for excessive
mechanical wear without removing the cover.
Mag-Hytec
suggests using this oil from Lubrication Engineers. This gear oil
has undergone extensive testing and was rated excellent results.
Mag-Hytec also sells this oil.
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Maintenance:
The Mag-Hytec cover is constructed of high quality aircraft
aluminum and has a powder-coated finish. The bolts and washers are
stainless steel. These components require no maintenance. From time
to time you may wish to check the oil level and monitor the wear in
your differential. With the Mag-Hytec cover this can easily be
accomplished by removing the dipstick assembly using a 1/4allen
wrench. You will probably notice some fuzzy metallic particles on
the magnetic end of the dipstick: this is normal wear. Wipe the
dipstick clean and reinstall (thread all the way in), remove the
dipstick and check the oil level. If the level is between the high
and low marks on the dipstick, apply a thin film of oil on the
dipstick assembly O-ring and reinstall the assembly snugly (20 in.
lbs.). DO NOT OVER TIGHTEN. We suggest you follow the manufacturer
recommendations for the gear lube drain intervals. You may change
your gear lube without removing the Mag-Hytec cover. Park your
vehicle on level ground with the parking brake applied. Position a
drain pan under the drain plug located at the bottom of the pan and
remove the drain plug assembly. You may notice metallic particles
on the magnetic drain plug. This is normal wear. (If you notice any
larger chips of metal on the magnetic portion of the plug, further
inspection should be performed. We suggest that a professional
mechanic who specializes in drive train components perform this
inspection.) Remember to clean the drain plug assembly prior to
reinstallation. Apply a thin layer of oil to the drain plug O-ring
and reinstall (30 in. lbs.). DO NOT OVER TIGHTEN. Follow the
procedure for filling the differential. Note: When checking the
oil level remember to thread the dipstick assembly in by hand until
it's snug against the o-ring. Should it become necessary to
remove your Mag-Hytec cover for any reason, the Mag-Hytec cover
O-ring may be reused. DO NOT USE ANYTHING TO PRY THE COVER FROM THE
DIFFERENTIAL HOUSING. THIS WILL DAMAGE THE O-RING. If you have
damaged the O-ring, you may obtain a replacement. If you need to
reinstall the cover and no O-ring is available, you may run a bead
of RTV silicone or gasket on the Mag-Hytecs mating surface face and
reinstall the cover in the conventional manner. During your
vehicles use, you may come in contact with water above the axle
seals or above the axle breather. You should inspect your gear
lubricant at the earliest opportunity. Do so by following the oil
level check procedure. If water is detected, follow the drain
procedure and refill your differential following the fill procedure
Conclusion:
The differential covers are very impressive with the quality and
workmanship coming from Mag-Hytec. These covers deliver
functionality, a tough look, and should provide years of trouble
free service. Maintenance is a breeze using these covers. We've
already had some positive comments on these covers and they really
set your vehicle apart from the others. By far, these are the best
covers we've ever seen and are worth every cent. Be sure to call
Mag-Hytec or stop by their site and let them know Off-Road.com sent
you!
Mag-Hytec
offers covers for other applications which includes Dana 44, Dana
70, Dana 80, Dana 60, GM 10-8.5, GM 14-10.5, GM 14-9.5, Ford
10-8.8, and Ford 12-10.25. They also have transmissions pans for
the Dodge 727, Ford E4OD, and GM 4L80E.
Mag-Hytec, Inc.
14718 Arminta St.
Van Nuys, California 91402
(818) 786-8325
(818) 786-0560 (FAX)
E-Mail: info@mag-hytec.com www.Mag-Hytec.com
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