Hello fellows just wanted to get some advice on the New style Aluminum Diff cover. Let me start by saying my Trk is a 97 F-250 HD Supercab 7.3l with 10.25 12 bolt Sterling rear Diff. Some years ago my local Quick Change oil and lube center stripped the Hex on my fill plug for the rear diff. Since that time I installed a fill plug in the OEM steel diff cover. My question is has anyone installed a fill and or drain plug in the new style aluminum diff cover Ford Part # 8C3z-4033A and if so are you happy with the results, and what specific size parts components were used?

I presently have ABS light lit on dash and am pretty sure it's the rear diff VSS sensor. I have already purchased the OEM Ford VSS part and thought I would install the new Aluminum diff cover w/fluid change at the same time and kill three birds w/one stone. My problem herein lies with the stripped fill plug and no way to refill the rear diff once I change to the new cover. Unless I-1. Remove OEM fill plug w/easy-out or some other method? 2. Or drill and tap to install a fill plug in the new style aluminum cover?

What I would like to do is to drill and tap the aluminum cover for a fill and drain plug, however at this point I have only seen pictures of the Aluminum cover and don't know if there is enough meat thickness in the proper area's to accomplish this task and do it properly to avoid any leaks or possible cracks in cover, any advice and all idea's are welcomed!

Which approach would you guys take? Thanks for all advice and help!

 

First of all, welcome to the site!

Honestly the approach I prefer for filling the rear diff is to fill it through the hole for the VSS. That doesn't exactly answer your question about the aluminum cover, but filling it through the hole for the VSS is about 10 times easier than using any fill hole that I have ever found. The one catch is that you have no way of telling when it is full, but if you're going to pop the cover and you lose all your oil, then you just fill it to the stock capacity.

If I recall correctly the manual calls for 3 1/2 quarts of oil, and if it is a LS axle you will have to add the ever pleasant smelling LS additive. A lot of guys are using Synthetic 75w 140 and not needing the LS additive, though. You just have to listen to see if it is chattering or not, then add the little bottle of fragrance if it does... FWIW, it doesn't hurt things to have a little extra oil in there, so if you decide to put 4 quarts in it, it won't hurt anything. I wouldn't go much higher than that though because you run the risk of "whipping" the oil and making it froth, which makes it lubricate poorly.

Oh, and another thing For a few dollars more Riffraff Diesel makes a custom aluminum rear cover that has your fill and drain holes built in. Check it out:
Riffraff Diesel: Riffraff Diesel Rear Diff Cover

Made in USA, O-ring seal (no more RTV), fill and drain plugs, and it looks great. You won't find a better place for customer service either.

 

Most of us fill the rears though the VSS. Much easier that way. To drain, I always take the cover off to inspect.

 

IMHO I wont drill and tap the aluminum cover. If you use syntetic oil, you dont need to change it soon. And fill it through the VSS.
This thread remember me this one:
https://www.ford-trucks.com/forums/6...ver-cheap.html

 

Very good suggestion filling through the VSS I didn't even think of that. My truck is all OEM except for the 6637 air filter mod w/the new style Ford air intake to turbo, hose and bracket w/133,000 original miles. Have D&R rear diff only once before and used the Royal Purple 75W-140 syn w/friction mod works very well and have had no problems.

Think I'll put your advice to good use and fill through the VSS once I have R&R rear diff w/new aluminum cover and save myself alot of time, money and headaches. I have thought about the nice covers like the one from riffraff and others like Hytec but can't justify the cost. My trk has been long since paid for and I don't even tow anything w/it anymore, had a few boats and some trailers in the past but sold them all, so I just pretty much use it for transportation. It's certainly more expensive to maintain this trk properly over a gasser but it beats the alternative of having a huge payment on a new one w/incressed ins rates.

Will post bennies to ya if possible.

Thanks for the advice and help!

 

That's what's great about our diff covers, they seal with an o-ring rather than RTV so you have much less clean-up. Not to mention it is easier to drain from a hole than prying the pan off.

 

Cool, Well I'd love to test one out, so why dont you send me one? :P

Haha.

You told me about the cover, but I never thought to ask you about that stuff.

I am dreading taking my diff cover off and looking inside. Everything is working, so I dont wanna know anything I cannot afford it.

 

DIYMechanic, Talyn, RÖENTGEEP bennies sent to ya.
Thanks to all for your help, idea's and suggestions. This is a great site with many great members.

GSCPSD

 

Your welcome, we love to help here.

 

X2 on that. anytime, and another WELCOME for you.

 

Clay, in your ad Riffraff Diesel: Riffraff Diesel Rear Diff Cover
says: " we use a Vitron o-ring" is that correct or is should say Viton?

 

WOW, with your bennies I just noticed that I got my 5th green been. Thanks a lot my friend.

 

VITON is the correct spelling.

 

I just reread love riffraff ...i need one of those covers!