Product Reviews

Mag-Hytec Installation Recommendations.

The following tools will be needed to install the Mag-Hytec 14-bolt cover:

9/16 socket wrench and driver (for removing the old cover) 
1/4 allen bit with a 3/8 ratchet drive (1/4 allen key may be used) 
5/16 allen bit with a 3/8 ratchet drive 
3/8 drive torque wrench 
Gasket scraper 
Wire brush 
Smooth flat file 
Oil drain pan (minimum 5 Qt. capacity) 
New gear lube API Spec. GL-5, MT-1 (Amsoil synthetic is recommended.) 
Amsoil is available by calling SD Enterprises at (310) 322-8532 
Friction modifier (for limited slip equipped differentials only) 

This kit should include the following parts. If any of the parts listed below are missing, e-mail Mag-Hytec@Mag-Hytec.com. 
Number    Quantity    Item
     1                 1             Mag-Hytec Differential cover with O-ring
     2                12            3/8-16 stainless allen cap screws
     3                12            3/8 stainless washers
     4                 1             Drain plug assembly with magnet and O-ring (installed)
     5                 1             Dipstick assembly with magnet and O-ring (installed)
     6                 1             Stainless steel oil level reference plug with O-ring (installed)
     7                 1            1/8 pipe plug (for optional temperature sender not included)

A word of caution to the installer / 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 no other vehicle component comes in contact with the Mag-Hytec cover. Contact with any vehicle component, or the making of any modification to the Mag-Hytec cover, automatically voids the warranty. Mag-Hytec assumes no liability, expressed or implied, for damage or injury to persons or property.

Installation:
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 work space prior to starting the installation.

1.Park your vehicle on level ground and apply the parking brake 
2.Position a drain pan under the differential to catch the old gear lube. 
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 cover 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. A wire brush may be required to aid in cleaning the gasket surface. 
7.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's O-ring to seat. 
8.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. 
9.Using gear lube, apply a light 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 stainless allen cap screws to 25-30 ft. lbs. 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 TEFLON THREAD SEAL ON THE SENDER'S PIPE THREADS DO NOT OVER TIGHTEN! 
13.Remove the dipstick assembly, and add in the new gear lube. Your new cover will
take approximately 5 1/4quarts for the Dana 70 and 6 2/3quarts for the Dana 80.
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 (20 ft. lbs.). BE CAREFUL TO NOT OVER TIGHTEN THE ASSEMBLY.

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. 14.If you have a limited slip differential, be sure to add the appropriate amount of friction modifier. We have had excellent results with the Chrysler friction modifier, and it is compatible with Amsoil synthetic gear lubes. (ONE TO 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 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 ft. lbs.). DO NOT OVER TIGHTEN.

We suggest you follow the manufacturers 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 O-ring and reinstall (20 ft. lbs.). 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 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 by e-mailing Mag-Hytec@Mag-Hytec.com. 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.

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Source
E-Mail us at: info@mag-hytec.com Web Site: Mag-Hytec.com	Mag-Hytec, Inc. Van Nuys, California 14718 Arminta St. Van Nuys, California 91402 (818) 786-8325 (818) 786-0560 (FAX)