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How to: Installing PML Differential Cover (9.25" diff)

Waterfowler41

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Here is a quick run through of how to install the PML differential cover for 2019+ Ram 1500’s This is part number 9518 and fits the 9.25” rear diff.


1. Before starting this project make sure you look in your manual and very the correct oil based on your rear gear ratio.
  • 3.21 and 3.55: This gear ratio requires 75W-90 (MS-A0160). 3 quarts for the PML capacity.
  • 3.92 (Rebels): This gear ratio requires 75W-140 (MS-8985). 3 quarts for the PML capacity.
  • All the rear-ends require 5+ oz. of Mopar Limited Split Additive (MS-10111). You will need to buy two bottles of this since with the PML cover you will need ~6 oz.

be08080be6e7c8e15ee44591167e2c86.jpg



2. Remove the 3 plastic clips that are routing wires around the top of the direction. I used a flat head to remove them. Tuck the wires on the otherwise of the diff.

bf8dc9be7026f14b52068fe86501fc58.jpg



3. Remove the 4 bolts holding the sway bar to the axle and slowly lower it down. This will allow you clearance when removing the stock cover and installing the PML cover.

4. Slide an oil pan under the differential and begin removing bolts. Leave on loosely threaded in on the top and the bottom of the differential casing. This will allow you to open the cover without it dropping down.

5. Carefully using a flat head screw driver, slide it between the OEM cover and the housing and “break” the RTV seal. Oil should start to flow out. You will need to do this at a few points around the diff housing in order to unseal the RTV.

84369466759faab39121e212e517fc80.jpg



6. Remove the factory cover, clean, and set aside.

7. Now the fun part starts, using a razor blade start scraping off all the orange RTV on the diff housing. Take your time doing this. You want to make sure the surface is perfectly smooth so the new gasket seats cleanly against it.

a270db743c34025ecb4573f554ebc58b.jpg



8. Find the three double threaded bolts. You will need to reuse these so you have a spot to reattached those wires. If you do not remember which holes those screws go in here’s where they go.

ddb9ac17e7d82ca11bd2e9a81d3e171c.jpg



9. Using the supplied gasket from PML begin to carefully install the cover. Start with the top middle bolts and work your way around the cover. Once everything is loosely installed you can start tightening all the bolts down. Tighten them down in a star pattern to ensure a proper seal.

10. After the cover is tightened, double check the drain plug is tight.

11. Reinstall the sway bar. Check for clearances.

2817dc76bb6d1698a20426d5f54822ba.jpg



12. Remove both the fill plug and the dip stick plug. Using the following fill sequence to help with initial mixing of oil and additive.
a. Pour in 1 qt of oil.
b. Pour in ¾ bottle of additive.
c. Pour in second qt. of oil.
d. Pour in remaining additive to equate to ~ 6 oz.
e. Top of with rest of oil until oil starts to come out of the dipstick plug.

13. Clean up everything and drive the truck around slowly. Listen for any odd noises or chattering from rearend (will happen if not enough additive is added).

14. After driving a few miles, park the truck and check for leaks.

15. Periodically check for leaks in the first couple hundred miles.

16. Enjoy your new cover!

4c269d3da356be9234276121a2f11781.jpg



Here is my Youtube install video of this cover for those who need it.
 
Last edited:

SpeedyV

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Here is a quick run through of how to install the PML differential cover for 2019+ Ram 1500’s This is part number 9518 and fits the 9.25” rear diff.


1. Before starting this project make sure you look in your manual and very the correct oil based on your rear gear ratio.
  • 3.21 and 3.55: This gear ratio requires 75W-90 (MS-A0160). 3 quarts for the PML capacity.
  • 3.92 (Rebels): This gear ratio requires 75W-140 (MS-8985). 3 quarts for the PML capacity.
  • All the rear-ends require 5+ oz. of Mopar Limited Split Additive (MS-10111). You will need to buy two bottles of this since with the PML cover you will need ~6 oz.

be08080be6e7c8e15ee44591167e2c86.jpg



2. Remove the 3 plastic clips that are routing wires around the top of the direction. I used a flat head to remove them. Tuck the wires on the otherwise of the diff.

bf8dc9be7026f14b52068fe86501fc58.jpg



3. Remove the 4 bolts holding the sway bar to the axle and slowly lower it down. This will allow you clearance when removing the stock cover and installing the PML cover.

4. Slide an oil pan under the differential and begin removing bolts. Leave on loosely threaded in on the top and the bottom of the differential casing. This will allow you to open the cover without it dropping down.

5. Carefully using a flat head screw driver, slide it between the OEM cover and the housing and “break” the RTV seal. Oil should start to flow out. You will need to do this at a few points around the diff housing in order to unseal the RTV.

84369466759faab39121e212e517fc80.jpg



6. Remove the factory cover, clean, and set aside.

7. Now the fun part starts, using a razor blade start scraping off all the orange RTV on the diff housing. Take your time doing this. You want to make sure the surface is perfectly smooth so the new gasket seats cleanly against it.

a270db743c34025ecb4573f554ebc58b.jpg



8. Find the three double threaded bolts. You will need to reuse these so you have a spot to reattached those wires. If you do not remember which holes those screws go in here’s where they go.

ddb9ac17e7d82ca11bd2e9a81d3e171c.jpg



9. Using the supplied gasket from PML begin to carefully install the cover. Start with the top middle bolts and work your way around the cover. Once everything is loosely installed you can start tightening all the bolts down. Tighten them down in a star pattern to ensure a proper seal.

10. After the cover is tightened, double check the drain plug is tight.

11. Reinstall the sway bar. Check for clearances.

2817dc76bb6d1698a20426d5f54822ba.jpg



12. Remove both the fill plug and the dip stick plug. Using the following fill sequence to help with initial mixing of oil and additive.
a. Pour in 1 qt of oil.
b. Pour in ¾ bottle of additive.
c. Pour in second qt. of oil.
d. Pour in remaining additive to equate to ~ 6 oz.
e. Top of with rest of oil until oil starts to come out of the dipstick plug.

13. Clean up everything and drive the truck around slowly. Listen for any odd noises or chattering from rearend (will happen if not enough additive is added).

14. After driving a few miles, park the truck and check for leaks.

15. Periodically check for leaks in the first couple hundred miles.

16. Enjoy your new cover!

4c269d3da356be9234276121a2f11781.jpg



Here is my Youtube install video of this cover for those who need it.
Nice write-up! On the fluid recommendations, keep in mind that the 3.92 ratio is not limited to Rebels; it's a very popular option. Also, the (highly-elusive) "Max Tow" version of the 3.92 uses Dana SAE 80W-90 and does NOT use the Mopar Limited Slip Additive.
 

Waterfowler41

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Nice write-up! On the fluid recommendations, keep in mind that the 3.92 ratio is not limited to Rebels; it's a very popular option. Also, the (highly-elusive) "Max Tow" version of the 3.92 uses Dana SAE 80W-90 and does NOT use the Mopar Limited Slip Additive.

Thanks will update that!
 

Waterfowler41

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I watched this whole series. Good stuff.


Unfortunately they don’t make the cover for our trucks so it’s sort of a moot issue. Certainly an awesome looking cover and in theory the design makes sense.

Since I question everything I see I tried to find additional real life info from more than Gale Banks showing high cap diff covers were the root cause failure of gears but nothing on the ol’ interwebs corroborated the video.
 

AnthonyD1978

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Unfortunately they don’t make the cover for our trucks so it’s sort of a moot issue. Certainly an awesome looking cover and in theory the design makes sense.

Since I question everything I see I tried to find additional real life info from more than Gale Banks showing high cap diff covers were the root cause failure of gears but nothing on the ol’ interwebs corroborated the video.

They have a whole series of videos on the subject with very good testing. I would watch the whole series. The OEM diff covers are designed much better in most cases.

Part 1
 

Waterfowler41

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Good testing but not 3rd party testing. Again I don’t doubt the design is great but I couldn’t find any evidence from real failures supporting how “bad” Banks says other covers are.
 

Waterfowler41

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They have a whole series of videos on the subject with very good testing. I would watch the whole series. The OEM diff covers are designed much better in most cases.

Part 1

I spoke with another company that makes diff covers about the Banks videos. Their product was actually featured in the videos. They said it’s Banks being a sales engineer with theories to promote his own covers. They also agree that there was no real world basis for these “high cap covers” are bad claims. They also pointed out Banks’ covers are made in China.

So anyways make of it what you will.
 

56 Pontiac

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Here is a quick run through of how to install the PML differential cover for 2019+ Ram 1500’s This is part number 9518 and fits the 9.25” rear diff.

...
16. Enjoy your new cover!

4c269d3da356be9234276121a2f11781.jpg
Thanks for the excellent instructions.

How did you get a RED cover? The only offer raw casting or black.

Thanks,
Davve
 

Stryker6040

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Does lubelocker make a gasket for this rear end? Is this the only cover out for 2019+ new body, seems like all the other 9.25 are for front HD truck axles
 

Scram1500

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Does lubelocker make a gasket for this rear end? Is this the only cover out for 2019+ new body, seems like all the other 9.25 are for front HD truck axles
Yes, I've had one in my Amazon cart for a while now waiting until the 30K mile mark. Got the part number from this thread


 

Stryker6040

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Yes, I've had one in my Amazon cart for a while now waiting until the 30K mile mark. Got the part number from this thread



Nice thank you!
 

Rick3478

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Does lubelocker make a gasket for this rear end? Is this the only cover out for 2019+ new body, seems like all the other 9.25 are for front HD truck axles
B&M/Holley 10306 or 11306, G2 Axle Torque or Hammer
 

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