• 9/16 socket wrench and driver (for removing the old cover)
• 3/16 allen bit with a 3/8 ratchet drive (3/16 allen key is furnished)
• 1/4 allen bit with a 3/8 ratchet drive
• 5/16 allen bit with a 3/8 ratchet drive
• 3/8 drive torque wrench
• Gasket scraper
• Smooth flat file by 8 to 12 in. long
• Oil drain pan (minimum 8 Qt. capacity)
• New gear lube API Spec. GL-5, MT -1 ("LE" 607 for severe service and extreme HD applications and temperatures of -20 to 240 deg. F). ("LE 9920 75-140 Synthetic") for warranty reasons and extreme low and high temperatures of -50 to 280 deg. F). The Stuart Friction Modifier bottled by Torco Co. (for "limited slip" differentials only) 4 oz. per 3 qts. of gear oil. The "LE" Gear Oil and the Friction Modifier can be purchased at Mag-Hy:tec.

Parts Content:

1) - Mag-Hytec Differential cover with O-ring ARP 568-275 (installed)
11) - 3 / 8-16 stainless allen cap screws (Torque 20-25 ft. Ibs)
12) - 3 / 8 stainless AN washers
1) - Drain plug assembly with magnet and O-ring ARP 568-910 (installed)
1) - Dipstick assembly with magnet and O-ring ARP 568-910 (installed)
1) - Oil level reference plug with O-ring ARP 586-904 (installed)
1) - 1/8 pipe plug (for optional temperature sender not included) Dipstick, Drain plug, Reference plug and
1) - 1/8 pipe plug (Torgue to 30 in. Ibs)

A word of caution to the installer I vehicle owner:

The Mag-Hytec cover is designed to fit the factory Dana axles as supplied as original equipment. However, in some applications, or because of the use of certain factory options and/or after market equipment, there may be clearance problems between your Mag-Hytec cover and other vehicle systems (specifically some rear sway bars). It may be necessary to install spacers or shims to lower the sway bar. It is the responsibility of the vehicle owner/cover installer to ensure that there is no contact with Mag-Hytec cover. Contact with any vehicle component or the modifying of the Mag-Hytec pan voids the warranty. Mag-Hytec assumes no liability, expressed or implied, for damage or injury to persons or property.

Installation:

1. Park your vehicle on level ground and apply the parking brake.

2. Position a large drain pan under the differential to catch the fluid.

3. Remove the 10 existing bolts, starting at the bottom.

4. 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 pan off.

5. Allow all of the old gear lube to drain.

6. Using a gasket scraper, carefully remove all of the old gasket material (dried silicone) from the housing.

7. Use clean lint free rags to wipe 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's O-ring to seal.

8. Before installing the new Mag-Hytec cover, check the gasket matting surface on the 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.

9. Using gear lube, apply a thin layer of oil to the Mag-Hytec cover O-ring.

10. 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."

11. Using a 5/16 hex bit and 3/8 drive torque wrench, torque the zinc plated allen cap screws to (20 -25 ft. Ibs.) in a "cross tight" pattern.

12. 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. "TIGHTEN" both the DRAIN PLUG and 1/8 PIPE PLUG TO (30 in. Ibs) DO NOT OVER TIGHTEN.

13. Remove the dipstick assembly and add in the new gear lube. Your new cover will take approximately 6 qts. to fill ( to bottom of axle) for the Dana 70. 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 in by hand until it snugs against the O-ring. Remove the dipstick assembly and check the level. If the oil level is at the full line, apply a thin film of oil to the dipstick assembly O-ring and reinstall. Tighten snugly to (30 in. Ibs). DO NOT OVER TIGHTEN THE ASSEMBLY. Drive at least 25 miles and check oil level. 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 high oil level is the top line on the Dipstick (The bottom of the axle). The low oil level is the bottom line on the dipstick (the bottom inside of the axle tube). Once you have established the correct level, scribe a reference line on your dipstick for future reference and fill the differential.

14. If you have a "limited slip" differential. be sure to add to appropriate amount of friction modifier. We have had excellent results with Stuart Friction Modifier product sold under many private labels can be purchased at Dodge, Ford or Mag-Hytec and it is compatible with the "LE" and Amsoil gear lubes. One 4 oz. bottle per 3qts. of gear oil (TWO 4 OZ. CONTAINERS SHOULD PROVIDE THE DESIRED RESULTS).

Maintenance:

The Mag-Hytec cover is constructed of high quality aircraft aluminum and has a powder-coated finish. The bolts are zinc plated allen head screws and the 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 1/4 allen 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 by hand until it bottoms out on the a-ring. 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 a-ring and reinstall the assembly snugly. (30 in. Ibs) DO NOT OVER TIGHTEN. We suggest you follow the manufacturer's 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 "fuzzy" 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 this inspection be performed by a professional mechanic who specializes in drive train components.) Remember to clean the drain plug assembly prior to reinstallation. Apply a thin layer of oil to the drain plug a-ring and reinstall. (30 in. Ibs) DO NOT OVER TIGHTEN. Follow the procedure for filling the differential. Should it become necessary to remove your Mag-Hytec cover for any reason, the Mag-Hytec cover a-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 a-ring, you may obtain a replacement by calling 818-786-8325. If you need to reinstall the cover and no a-ring is available, you may run a bead of RTV silicone or use a gasket on the Mag-Hytec's matting surface face and reinstall the cover in the conventional manner. During your vehicle's 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.