08+ Rear Diff Cover Swap

Justin@DP-Tuner

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Ever since I changed my diff covers to chrome ones about 6 months ago, I have had a constant leak both up front and back. It has driven me nuts. I have pulled the covers and tried to re-seal a couple of times, but it did not work so I had enough.

I really liked the look of the 08+ rear cover. It is finned aluminum to help with heat, and the elements wont be able to effect it like they did on the stock stamped steel one. Another benefit was how thick it is where the bolts go through. After going through Sunrise Ford and seeing how cheap it was I figured it was the best way to go. Oh and by the way, you will not find it cheaper ANYWHERE... Period... Sunrise beat everyone's price by a long shot. They have a new online store and if you order on there you can get $10 knocked off your order just by writing "diesel" in the promo code box. They also offer free shipping on smaller items which also helped with the already low price.

I had the diff cover delivered to my door for $44.04

After about $6 in new bolts I was ready to put it on. If anyone who hasn't already done this plans on doing it, you will need to buy longer bolts than your stock ones. The size bolt you will need is 5/16-18x1.25. I just bought some grade 8 bolts that I thought would look good. I also used lock washers for added security.

The job was pretty straight forward. Pull the old cover off, let it drain, clean surface, add sealant to the new diff cover, bolt it on, and add some 75w150 full synthetic gear oil until it is full. The gear oil will cost you more than the cover.

Here are a few pics...

reardiff1.jpg


reardiff2.jpg


reardiff3.jpg


As you can see in the pics, the old covers liked to leak which I could not stand.

Tomorrow I plan on pulling off the front chrome one, re-painting my original Dana cover, and putting that one back on. Ill post pics of that too.

I know this has probably been done thousands of times, but you rarely ever see up-close pictures. I am very satisfied with the look, and for the price you can't go wrong.
 
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Justin@DP-Tuner

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Where'd you go to get the bolts. I'm about to do this too

Ace Hardware... I'm sure any hardware store will have what you need though. I would have liked to do Stainless Allen head bolts, but they were $2.29 a piece! That is just way too much for a bolts that is barley ever seen.
 

MossBack

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Ace Hardware... I'm sure any hardware store will have what you need though. I would have liked to do Stainless Allen head bolts, but they were $2.29 a piece! That is just way too much for a bolts that is barley ever seen.

I paid 7 bucks for 12 stainless bolts with lock washer and flats all stainless. Not sure where ur at but somewhere industrial like fastenal or something should be cheaper.

Ill get a shot of mine in the morning .

Looks good!

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Justin@DP-Tuner

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I paid 7 bucks for 12 stainless bolts with lock washer and flats all stainless. Not sure where ur at but somewhere industrial like fastenal or something should be cheaper.

Ill get a shot of mine in the morning .

Looks good!

Sent from my PC36100 using Tapatalk 2

Are they Allen head? I could have gotten standard stainless for around that price but I like the look of the grade 8's matched with aluminum.

Thanks!
 

MossBack

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Yea Allen I was going to paint it black but ended up polishing it.

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MossBack

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I was thinking about polishing it, but figured it would be a PITA LOL

Yea 2.5 hrs worth of pita.

I also painted my axle ID tag

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Layson

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I have an 08 diff cover on mine as well! I had mine powdercoated black!!

photo-13.jpg
 

SouthFlstrokin'

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i forgot i did this mod a LONG time ago. looks good man. be careful i hear they have issues with cracking now...
 

Dmstrucks02

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Easy..... Just got it out of the shop for tie rods and drag link but that's no excuse for the past year of an oily cover lol.
We phucked this thread all to hell
 

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