Installation Guide

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Rear Differential Cover for Sprinter by Agile Offroad

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Installation Manual

General Information

The AO Sprinter Diff Cover is designed to be installed on 2007+ Sprinters. We recommend that the AO Diff Cover be installed by an authorized AO dealer (refer to agileoffroad.com to find a dealer near you).

Read the instructions completely before starting the installation process.

Parts Included

Part # AOR91122(black) AOR911225(orange):

  • 1 x AO Sprinter Diff Cover
  • 1 x Diff Cover Gasket
  • 1 x AO Anodized Fill Plug
  • 12 x Mounting Bolt

Tools Needed

  • 4mm Allen/Hex Socket (2500 vans)
  • 17mm AllenHex Socket (some 3500 vans)
  • Gasket Scraper
  • E12 Torx Socket
  • 3/8” Ratchet Driver
  • 13mm Socket
  • Blue Loctite
  • Drain Pan

Installation Steps

1

Locate the factory drain plug found on the passenger side of the differential.

2

Use a 14mm allen/hex socket to remove the drain plug. Have drain pan ready to catch oil.

3

Allow differential to drain for several minutes before removing cover. The oil will drain out quicker when warm

4

Use an E12 torx socket to remove the 10 differential cover bolts.

5

Use the gasket scraper to pry the cover off of the differential housing.

6

Use the gasket scraper to clean off any remaining gasket residue. Wipe clean.

7

Prep supplied bolts by adding blue loctite. Orient gasket to AO Diff Cover mounting bolt holes.

8

Place supplied gasket onto AO Diff Cover with letter side facing cover and blank side facing differential. Install one bolt in top hole.

9

Place AO Diff Cover w/gasket on housing and hand tighten top bolt. Install remaining 9 bolts.

10

Tighten bolts using a criss-cross sequence. Torque to 16 ft lbs.

11

Re-install factory drain plug.

12

Use a 3/8” drive ratchet to remove the fill plug.

13

Fill differential with gear oil. Refer to your manual for specific year/model recommendation.

14

The oil level should be at the bottom of the fill hole.

15

Use a 3/8” drive ratchet to install fill plug. Tighten until fill plug makes contact with AO Diff Cover.

16

Congrats!

Your installation is complete.