Rear Differential Cover
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Senior User
Joined: Apr 2012
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From: Orlando, FL
Rear Differential Cover
Not sure if this should go in here or the F250/F350 forum but since it is a 6.0L PSD I am going with here (besides I like you guys!!! 
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I have a 2004 F350 FX4 SRW offroad with 8 foot bed. It just had the 135.000 mile service done (sorta). As part of the 150,000 mile service the rear axle fluid is supposed to be changed. The cover of the differential is oxidized and very flaky. I plan on replacing it as part of the 150k service. I couldn't find a part number for it from FORD or a cost....
I went to Auto zone and for $40 I can get a chrome plated steel. For $150 I can get polished aluminum cover. Online for about $260 I can get a Mag hytec aluminum cover with powder coating and extra capacity and or Afe Power cover that is similar.... I am sure there is others..... lots of others.... just curious if the oversize it worth it.... and if steel or aluminum is better Just wanted everyone's take on it?
)I have a 2004 F350 FX4 SRW offroad with 8 foot bed. It just had the 135.000 mile service done (sorta). As part of the 150,000 mile service the rear axle fluid is supposed to be changed. The cover of the differential is oxidized and very flaky. I plan on replacing it as part of the 150k service. I couldn't find a part number for it from FORD or a cost....
I went to Auto zone and for $40 I can get a chrome plated steel. For $150 I can get polished aluminum cover. Online for about $260 I can get a Mag hytec aluminum cover with powder coating and extra capacity and or Afe Power cover that is similar.... I am sure there is others..... lots of others.... just curious if the oversize it worth it.... and if steel or aluminum is better Just wanted everyone's take on it?
Posting Guru
Joined: Apr 2008
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From: Green Lane, Pa.
The 2008/09/10 F250 rear covers are not aluminized, there finned cast aluminum covers.
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Senior User
Joined: Apr 2012
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From: Orlando, FL
I just bought the truck 2 months ago. I plan on towing. I have 2 motorcycles I want to transport around. While I would prefer to ride them to events carpal tunnel in both hands makes it difficult. As far as offroad not really.
Posting Guru
Joined: Oct 2006
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From: Francestown, NH
Mine didn't look too pretty either.
I opted to clean and repaint mine. The rust and flaking appeared pretty bad but once I got the cover off I saw there was plenty of good metal in the cover.
I did mine back in Oct 2011 and the paint still looks fine.
I opted to clean and repaint mine. The rust and flaking appeared pretty bad but once I got the cover off I saw there was plenty of good metal in the cover.
I did mine back in Oct 2011 and the paint still looks fine.
Logistics Pro
Joined: May 2004
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Spend 80.00 and get the cover from a 2008-2010 PSD, I did and am happy with it. They are aluminum with fins for cooling and they look awesome. Just remember you should probably think about getting new bolts for it as well....you can pick these up anywhere.
Also....don't forget to put in SYNTHETIC oil with the additive already in it or buy the additive for it, if not you will ruin your clutches back there.
IMO an expensive cover with an extra quart of fluid capacity isn't worth it....now if you're talking trans pans then yes.
Good Luck
Also....don't forget to put in SYNTHETIC oil with the additive already in it or buy the additive for it, if not you will ruin your clutches back there.
IMO an expensive cover with an extra quart of fluid capacity isn't worth it....now if you're talking trans pans then yes.
Good Luck
Senior User
Joined: Jul 2011
Posts: 179
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From: pittsburgh, pa
IMHO mag hytec is the bomb! In addition to the added fluid capacity, you can add a temp probe, it has a dipstick to check wear and fluid level, it has an inspection plug for correct filling, and most importantly a drain at the bottom to change fluid without removing the cover. Oh and gasket cement is not required to seal the cover as it has an o-ring seal. And it looks 
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Lead Driver
Joined: Jun 2007
Posts: 6,757
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From: Corvallis, OR
As others have said, go with the oem cover for '08+ diesel trucks. It is a cast, finned aluminum cover and a great value. You will need longer bolts to go along with it.
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Logistics Pro
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IMHO mag hytec is the bomb! In addition to the added fluid capacity, you can add a temp probe, it has a dipstick to check wear and fluid level, it has an inspection plug for correct filling, and most importantly a drain at the bottom to change fluid without removing the cover. Oh and gasket cement is not required to seal the cover as it has an o-ring seal. And it looks
Thanks for mentioning the longer bolts cartmanea.....I knew i changed them for a reason.....just forgot why
FTE Legend
Joined: Jul 2005
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From: Millersville, MD
If I were towing (I am), I would opt for the Mag-HiTec (or however it's spelled) as I want to put in a temp probe. But I tow much heaver than you. I'll replace my stock cover when it comes time to change the fluid.
2006 Bullet-Riddled 6.0
Joined: Sep 2011
Posts: 651
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From: Sac River Delta Ca.
I just changed both of my diffs last weekend and I am with Piolet, the guage of covers are heavy. I was surprised how rusty it was and how the paint was flaking.
I sandblasted them and primed and painted. The $40 chrome covers will get paint sooner than you think because of rusting imo.
Most important factor here is the new oil
I sandblasted them and primed and painted. The $40 chrome covers will get paint sooner than you think because of rusting imo.
Most important factor here is the new oil
Laughing Gas
Joined: May 2005
Posts: 1,082
Likes: 1
From: Illinois
This is a really good idea and it looks like it turned out very nice.
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Senior User
Joined: Apr 2012
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From: Orlando, FL
Sounds like a plan. I think I will pull the cover as part of the maintenance and then decide. I can either sand and spray or replace. Just out of the curiosity does the 08 OEM cover have a drain plug in it. The $150 dollar aluminum one from auto zone does.... not sure if that is worth the $70 dollars extra but that is another issue altogether
Logistics Pro
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No it does not have a drain plug....but in all seriousness, at the drain interval you want to remove the cover and clean all the collection of stuff on the magnet and clean the inside of the diff.....draining the diff and not removing the cover is not the right way to do it...IMO
The DANA covers are super thick and reliable, but not the best for cooling. If you are going to beat the $h*t out of the truck and possibly jam the diff into rocks, the stocker is the ONLY way to go.
The DANA covers are super thick and reliable, but not the best for cooling. If you are going to beat the $h*t out of the truck and possibly jam the diff into rocks, the stocker is the ONLY way to go.
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Senior User
Joined: Apr 2012
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From: Orlando, FL
I agree with you the cover should be pulled..... I like drain plugs for several reasons... mostly dealing with hot oil and less mess Not sure if you ever done a oil change and the oil you thought was cool was still boiling.... you get the idea... Course that is normally my wife's fault. You either have to hold a gun to her head or schedule a appointment to work on her van Anyways I like drain plugs to control the oil flow before removing the cover.... and it gives me something else to curse at and strip out
Here is the cover I was talking about that auto zone had for $150
Aluminum Differential Cover Dana 80 (13in. Ring Gear) Spectre 60919
Not sure if you ever done a oil change and the oil you thought was cool was still boiling.... you get the idea... Course that is normally my wife's fault. You either have to hold a gun to her head or schedule a appointment to work on her van Anyways I like drain plugs to control the oil flow before removing the cover.... and it gives me something else to curse at and strip out Here is the cover I was talking about that auto zone had for $150
Aluminum Differential Cover Dana 80 (13in. Ring Gear) Spectre 60919