When changing your gear oil, properly sealing the differential cover is critical to prevent leaks and ensure your differential runs smoothly. This guide is based on a real-life demonstration using a Jeep Cherokee XJ, featuring a Dana 35 rear axle with a 10-bolt cover. It’s highly relevant to a wide range of Jeep models and model years. Here's a step-by-step guide to walk you through the entire process with confidence.

Dana 35 Differential Cover Fitment

The SPELAB Dana 35 10 Bolts Rear Axle Differential Cover is compatible with the following Jeep models:

• 1984–1997 Jeep Wagoneer

• 1984–2001 Jeep Cherokee

• 1993–2004 Jeep Grand Cherokee

• 1986–1992 Jeep Comanche

• 1987–Present Jeep Wrangler

• 2001–2007 Jeep Liberty

How to Seal a Differential Cover and Gear Oil Change for Jeep Cherokee XJ？

By following the step-by-step guide below, you will be able to better maintain your axle

1. Removing the Differential Cover Bolts & Prep Work

Before sealing the differential cover, it's important to prepare everything in advance:

1.1 Preparation Before You Start

Make sure your vehicle is securely parked. Gather the necessary tools: wrenches, rags, sealant, a nylon brush, and other essentials.

1.2 Removing the Differential Cover Bolts

Loosen and remove all bolts securing the differential cover except for the top bolt, which should be left slightly threaded in. This helps hold the cover in place while the old gear oil drains, preventing a sudden spill.

1.3 Cleaning the Mating Surface

After removing the cover, use a nylon bristle brush, scraper, or paper towels to thoroughly clean the mating surfaces of both the cover and the housing. Avoid abrasive tools that could scratch the metal and compromise the seal.

1.4 Choosing the Right Sealant

There are many types of RTV and gasket sealants on the market. In the video demonstration, a budget-friendly option was used. When selecting yours, consider the temperature rating, compatibility, and intended use case.

2. How to Apply the Sealant

2.1 Application Techniques

Different people have different preferences, but here are the most common and recommended ways to apply sealant:

• Draw a continuous bead around each bolt hole and connect them for a closed loop.

• Apply a single line just inside the bolt holes along the inner sealing edge.

• If the mating surface is clean and flat, a thin layer of sealant is usually sufficient.

• If there are noticeable pits or gouges, use more sealant to fill the gaps.

• Use a nylon wheel or brush to give the sealing surface one final cleaning pass before installing the cover.

3. Reinstalling the Differential Cover & Refilling Gear Oil

3.1 Cover Installation Tips

Sealant only needs to be applied to one mating surface—there’s no need to coat both sides.
For vehicles like the Jeep Cherokee that aren’t lifted, start by hand-threading a few bolts to align the cover, then torque the rest to spec using a torque wrench.

3.2 Refilling Gear Oil

Be sure to choose the right gear oil for your vehicle and differential type. Limited-slip differentials may require additional friction modifiers.
In the demonstration, a thicker stabilizer and gear oil were used to address noise issues—but the noise persisted, suggesting worn bearings rather than a lubrication problem.

Make Gear Oil Changes Easier with the SPELAB Differential Cover

If you’re using an OEM stock differential cover, you’ll need to go through the full disassembly process described above every time you change your gear oil—which can be time-consuming and messy.

With the SPELAB aftermarket Dana 35 differential cover, gear oil changes become much simpler. It comes with a built-in drain plug at the bottom, allowing you to easily drain old oil by simply unscrewing the plug, attaching a hose, and using a funnel—no need to remove the cover.

Plus, SPELAB's cover features a sight glass, so you can visually check the oil level at any time. This not only simplifies routine maintenance but also helps extend the life of your differential.

Differential Cover For Dana 35 10 Bolts Rear Axle | SPELAB

High-Performance Differential Cover for Dana 35 Rear Axle

$199.98

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Conclusion

SPELAB is all about making your vehicle more efficient, easier to maintain, and ready for any terrain.Got a tip or experience of your own? Drop it in the comments—we’d love to hear how you maintain your axle!

FAQ

Q1: How do I know if my vehicle has a Dana 35 rear axle?
A1: The Dana 35 is commonly used as a rear axle in Jeep models. It’s easy to identify by its 10-bolt oval-shaped cover. You can count the bolts, check the shape, or reference your vehicle’s spec sheet. If in doubt, use your VIN or ask a professional mechanic.

Q2: Is sealant necessary when installing a differential cover? Can I just use a gasket?
A2: Sealant is highly recommended—even if the cover supports a rubber gasket. Sealant provides a more reliable, leak-proof seal, especially in off-road or high-heat conditions. SPELAB’s Dana 35 cover is designed to work best when installed with sealant.

Q3: What happens if the sealant is applied unevenly? Will it leak?
A3: Yes, poor sealant application can absolutely cause leaks. Too much, too little, or dirty surfaces will compromise the seal. Be sure to apply an even bead around all bolt holes, and ensure surfaces are clean and dry before installation.

Q4: How long should I wait before refilling with gear oil after sealing the cover?
A4: Most RTV sealants require 15–30 minutes of initial cure time before adding oil. Check your sealant’s label for specific instructions. Letting it set properly helps prevent early leaks.

Q5: Can the SPELAB Dana 35 differential cover be reused?
A5: Absolutely. SPELAB covers are built from high-strength aluminum, with durable threads and a sight glass for easy inspections. They’re designed for repeated use. Just make sure to clean the sealing surface and reapply sealant every time you reinstall it.