[romeroom]

OK, so I'm about to embark on removing the differential cover on my '95 AWD Astro with 195k miles--the cover has never been removed since the fluid in that part of the van has never been changed....(Go ahead. I would understand if you were to report me to the authorities for neglect. Justice must be served.)

The diff cover is so rusty you can barely make out some of the 8 bolts. I don't want to break any of the bolts, though I'm somewhat prepared for it. My plan is to soak with penetrating oil, tap lightly with a hammer, soak again, let it sit for a day or so, soak again with a few more taps of the hammer. Then try it.

Any other thoughts?

 

[astro355]

You have a ten bolt rear end meaning there will (should) be 10 bolts holding the cover on. Getting the surface rust off the heads of each bolt will be important so you don't strip any of the heads. Just take your time and don't rush it.

If you break a bolt off in the rear end housing, its not a big deal getting out the rest of the bolt, just time consuming.

 

[Leeann_93]

You have a ten bolt rear end meaning there will (should) be 10 bolts holding the cover on. Getting the surface rust off the heads of each bolt will be important so you don't strip any of the heads. Just take your time and don't rush it.

If you break a bolt off in the rear end housing, its not a big deal getting out the rest of the bolt, just time consuming.

Yep, 10 bolts (3 top, 3 bottom, 2 each side). And yes, breaking off a bolt isn't a tragedy, it's just a PITA. We spent 5 hours Saturday drilling out the 2 broken bolts, then twisting out the shells with vise grips. From there, it was easy-peasy. And I'm not sure the previous owner of my Bravada had ever had it done, either, so don't feel too bad.

Soak, tap, soak again, tap again. Just be aware: the bolts are washer head, which makes it harder to get the penetrating oil in, plus the bolts are fully captured in the housing, so there's no way to shoot oil in from the back. Use a wire brush on the heads and just around them.

 

['cudapaul]

Before you remove the diff cover make sure that you can get the fill plug out of the passenger side of the diff.
It takes a 3/8" square driver, you can use a 3/8" ratchet and extension to remove it.

It would be a little difficult if you could drain the fluid out, but not be able to fill it!

 

[romeroom]

Before you remove the diff cover make sure that you can get the fill plug out of the passenger side of the diff.
It takes a 3/8" square driver, you can use a 3/8" ratchet and extension to remove it.

It would be a little difficult if you could drain the fluid out, but not be able to fill it!

Very wise advice. Thanks to all. Don't know why I said "8" bolts; At age 48, it's been a number of years since I've been able to count to ten. Go figure... :banghead:

 

[romeroom]

I was just thinking, what about the front differential on the AWD? Does that need attention as well? How do you drain that one?