Change your rear diff oil if you haven't yet and clean those lockers!

[wobly]

Dude, all 3 of us had difficulty accessing several bolts. We're all 3 mechanics.

For the Power Wagon, the only accommodation I had to make to get the two bolts under the steering linkage was to remove my 3/8" extension. Plenty of room on the PW. I can't say anything about the non-PW models.

I decided at 25K miles, I needed to do the differentials. The oil in the front and rear diffs was black and had a bit of a sheen to it. I called a local place that carries Amsoil and she said the only 75W-90 Easy-Packs they had were held for other people, but she had the regular 1qt bottles at a lower price. I snapped them up and went home. Removing the rear was pretty easy. Moving the brake line bracket out of the way was the most challenging part. The reusable gasket was nice. Then, I had to figure out how to get the oil from the bottle into the diff. My cheap little transfer pump didn't work. The funnels that I had were the wrong angle. I was about to find a manila folder and make a funnel when I saw an old bottle of gear oil with the "nozzle top". I emptied it out and used that by pouring the oil from the new bottle to the nozzle bottle and then squirting it in the diff. It took me longer to come up with the solution to get the oil in the diffs than it did for the job itself. A 13mm deepwell for the rear and an electric ratchet made the job pretty painless. 10mm for the front.

 

[Overlander]

How many qts of transfer case fluid were required for this job?

 

[HEMIMANN]

I recall app. 2 quarts for transfer case.