aFe Power 46-70162 User manual

1
Instruction Manual P/N: 46-70162
Dana 40 –10 Bolt Differential Cover
Make: Jeep Model: Wrangler Year: 1997-2018
*Requires a minimum of 1.5”lift for proper clearance.

2
• Please read the entire instruction manual before proceeding.
• Ensure all components listed are present.
• If you are missing any of the components, call customer support at 951-493-7100.
• Ensure you have all necessary tools before proceeding.
• Ensure that your vehicle is cooled off before proceeding.
• Retain factory parts for future use.
Label
Qty.
Description
Part Number
A
1
Diff. Cover - Machined Fins
05-60257
B
1
Plug, Hex Hd Socket: 1/8 NPT (Zn Plt)
03-50029
C
1
Plug, 3/4-14 NPTF, 6 Deep Reach
03-50223
D
14
Washer, Flat: 5/16 AN S/S
03-50228
E
4
Screws, Socket Head Cap: 5/16-18 x 1-1/2 S/S
03-50368
F
6
Screw, Socket Head Cap: 5/16-18 x 3/4 S/S
03-50370
G
1
Washer, Aluminum: M12, 15.85MM OD
03-50384
H
1
Plug, M12 x 1.25
03-50385
I
1
O-Ring; 9.-1/2 ID x 9-3/4 OD x .139W (-272)
05-60285
J
2
Screws, Socket Head Cap: 5/16-18 x 1-3/4" S/S
03-50388
K
2
Spacer, Aluminum: .750L x .500 OD x .319 ID
03-50387
Installation will require the following tools:
1/2" socket, 14mm socket, 3/8 Rachet, 1/2" Rachet, 1/2" extension (3 inch), Panel
popper, Gasket Scrapper, Sand paper or file, & Drain pan.
Attention installer / Vehicle owner:
The aFe differential cover is designed to fit the factory axle supplied as original
equipment. For some applications, or due to the use of certain factory options
and / or aftermarket equipment, there may be clearance problems between the
aFe differential cover and other vehicle systems. It is the responsibility of the
installer / vehicle owner to ensure that no other vehicle component come into
contact with the aFe differential cover. Contact with any other vehicle
component, or any modification made to the aFe differential cover,
automatically voids the warranty. aFe assumes no liability, expressed or
implied, for damage or injury to persons or property.

3

4
1. Park your Jeep on level ground and apply the parking brake.
2. Position a drain pan under the differential cover.
3. Rear Axle Only: Using a panel popper, remove the electric locker wire loom (if
applicable).
4. Using a ½” socket and rachet, remove all but one of the top bolts from the
differential cover. Leave the bolt at the top. Loosen but do not remove.
5. Using a gasket scraper, start at the bottom of the cover and carefully (so as
not to gouge the housing metal) insert and pry off old cover. Allow the old
gear lube to drain. Remove differential cover.

5
6. Using a clean lint-free rag, wipe down the remaining oil from the housing and
the gasket surface. This surface must be clean for the O-ring to seal.
7. Before installing the aFe differential cover check the surface of the differential
housing for any irregularities. Should there be any, carefully remove high
spots using a smooth flat file or sand paper.
Note: DO NOT “ROUND OFF” THE FLAT GASKET SURFACE

6
8. Using some gear oil, apply a thin layer of oil to the aFe differential cover O-
ring. Install the O-ring on the back of the aFe differential cover.

7
9. Using the six (6) supplied 5/16 x 3/4"socket head cap bolts and washers,
install the aFe differential cover by starting the top three and the bottom
three bolts. Using the four (4) supplied 5/16" x 1 1/2" socket head cap bolts
and washers, install them in the remaining bolt holes. Tighten all the bolts
using a 1/4" allen wrench.

8
Note: Step 10 is only applicable to models with factory electric lockers.
10. Remove the two 5/16" x 3/4" bolts that are close to the fill plug. Install the
bracket on the differential cover using the two supplied 5/16" x 1 ¾", four
5/16 washers, and two 3/4" spacers. Push the wire on the bracket.

9
11. Place the M12 aluminum washer on the supplied drain plug.
12. Using a 14mm socket, install the drain plug in the differential cover and
tighten.

10
13. Fill the differential with gear oil until the oil runs out of the 1/8" NPT hole in
the front of the differential cover.
*If your axle is rotated different from stock, the 1/8" NPT will not be the full mark.
Please fill to the correct level before driving.
*Install Teflon tape on 1/8" NPT plug and magnetic fill plug
14. Using a 3/16" allen wrench, install the 1/8" NPT plug in the front of the
differential cover (as seen in top picture) and tighten.
15. Using a 1/2" drive extension, install the magnetic fill plug in the top of the
differential cover (as seen in bottom picture) and tighten.