Aftermarket Diff Covers
Super Moderator
Joined: Dec 2011
Posts: 13,335
Likes: 6,110
If the axle manufacturer offered an aluminum finned cover for higher GAWR versions of the axle, such as what Dana has done with their Dana 80, that Ford used to install in the F-450, then I would use that OEM cover in a heartbeat, no matter what conclusion the third video draws, and no matter what was said in the first two videos (I haven't seen them yet). The axle manufacturer is in the best position to know the most about the performance of their own axle products.
I'd go with what the axle manufacturer developed, and would assume that if the manufacturer saw fit to add an aluminum finned cover to one of their axles, they had a justifiable reason... because they are not in business to waste money on extra cost parts that have no real world benefit.... and their customers, like Ford, are constantly pressuring them to reduce every penny of product cost.
As it happens, my axle cover is seam welded to the housing, and there is no version of my axle that has a removable cover, nevermind a finned aluminum version of one. I once considered replacing the cover to the front axle, but couldn't find where Dana made one to fit the application and clear steering linkage, so I left it stock.
I'd go with what the axle manufacturer developed, and would assume that if the manufacturer saw fit to add an aluminum finned cover to one of their axles, they had a justifiable reason... because they are not in business to waste money on extra cost parts that have no real world benefit.... and their customers, like Ford, are constantly pressuring them to reduce every penny of product cost.
As it happens, my axle cover is seam welded to the housing, and there is no version of my axle that has a removable cover, nevermind a finned aluminum version of one. I once considered replacing the cover to the front axle, but couldn't find where Dana made one to fit the application and clear steering linkage, so I left it stock.
Thread Starter
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Laughing Gas
Joined: Apr 2014
Posts: 884
Likes: 5
From: Shreveport, LA
If the axle manufacturer offered an aluminum finned cover for higher GAWR versions of the axle, such as what Dana has done with their Dana 80, that Ford used to install in the F-450, then I would use that OEM cover in a heartbeat, no matter what conclusion the third video draws, and no matter what was said in the first two videos (I haven't seen them yet). The axle manufacturer is in the best position to know the most about the performance of their own axle products.
I'd go with what the axle manufacturer developed, and would assume that if the manufacturer saw fit to add an aluminum finned cover to one of their axles, they had a justifiable reason... because they are not in business to waste money on extra cost parts that have no real world benefit.... and their customers, like Ford, are constantly pressuring them to reduce every penny of product cost.
As it happens, my axle cover is seam welded to the housing, and there is no version of my axle that has a removable cover, nevermind a finned aluminum version of one. I once considered replacing the cover to the front axle, but couldn't find where Dana made one to fit the application and clear steering linkage, so I left it stock.
I'd go with what the axle manufacturer developed, and would assume that if the manufacturer saw fit to add an aluminum finned cover to one of their axles, they had a justifiable reason... because they are not in business to waste money on extra cost parts that have no real world benefit.... and their customers, like Ford, are constantly pressuring them to reduce every penny of product cost.
As it happens, my axle cover is seam welded to the housing, and there is no version of my axle that has a removable cover, nevermind a finned aluminum version of one. I once considered replacing the cover to the front axle, but couldn't find where Dana made one to fit the application and clear steering linkage, so I left it stock.
Hotshot
Joined: Dec 2014
Posts: 17,833
Likes: 3,119
From: Jersey Shore
I still have the Mag Hytec because I’m too cheap to get the OE Ford aluminum unit, and wanted the drain.
Back around 2002 I got into a pi**ing contest with DieselSite Bob over these on TDS, and how much to fill. Mag Hytec wants you to fill to their level, which was way over the stock fill plug on the carrier. I said no, the fill plug level was consistent with industry practice, set in place within SAE if you think Ford was cheating out on a pint of lube. It got long with Bob saying M-H knew better. I think it was HaulinHorses2 that took his truck in for a pinion leak, the dealer mechanic drained the lube down to the carrier fill level and said try that. Pinion leak went away.
As Y2K pointed out, manufacturers spend a lot of time working out levels and details. If I ever have the desire to remove my cover I’d show the little flap I installed in mine to not have that ledge that blocks fluid movement. Unless it’s broke loose over the last 200k miles and has gotten ground up.
I do wonder what got a burr under Gale Banks saddle though. These ain’t new.
Back around 2002 I got into a pi**ing contest with DieselSite Bob over these on TDS, and how much to fill. Mag Hytec wants you to fill to their level, which was way over the stock fill plug on the carrier. I said no, the fill plug level was consistent with industry practice, set in place within SAE if you think Ford was cheating out on a pint of lube. It got long with Bob saying M-H knew better. I think it was HaulinHorses2 that took his truck in for a pinion leak, the dealer mechanic drained the lube down to the carrier fill level and said try that. Pinion leak went away.
As Y2K pointed out, manufacturers spend a lot of time working out levels and details. If I ever have the desire to remove my cover I’d show the little flap I installed in mine to not have that ledge that blocks fluid movement. Unless it’s broke loose over the last 200k miles and has gotten ground up.
I do wonder what got a burr under Gale Banks saddle though. These ain’t new.
Fleet Owner
Joined: Apr 2012
Posts: 27,307
Likes: 549
From: Spanaway
Speaking of pinion leak I have to deal with mine soon. Soon as after I get back from Eastern Washington on my little trip.
I think I will take an extra quart with me just in case it gets bad.
I think I will take an extra quart with me just in case it gets bad.
Cargo Master
Joined: Nov 2015
Posts: 3,427
Likes: 940
From: Fort Worth, TX
I had a little pinion leak before a 500 mile trip to west Texas when I had my 02 f150. By the time we got back differential oil was dripping from the pass side leaf spring, wheel well, bed, etc. When I tore it all down, the pass side axle had a .030" deep circumferential groove where it contacted the inner bearing race. I believe the replacement axle from Ford was around $450. Do yourself a favor, bring more than a quart and check it often.
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Diesel User
Joined: Sep 2004
Posts: 216
Likes: 0
From: Berkshires, MA
New Product?
I smell a new product from Banks! The new cover will have a right inside and the cooling fins will give it the big bold FLAT look of the other covers. Basically a glorified stock cover with a dipstick.
Hotshot
Joined: Dec 2014
Posts: 17,833
Likes: 3,119
From: Jersey Shore
Sold the Mag Hytec before the market bottoms 
, got me a Ford cover for less than half the sale price.
Don't need no stinkin' cooling ears at the bottom of the pumpkin to catch things on the farm.
Don't need no stinkin' sight glass either.
Painted and installed.
, got me a Ford cover for less than half the sale price.Don't need no stinkin' cooling ears at the bottom of the pumpkin to catch things on the farm.
Don't need no stinkin' sight glass either.
Painted and installed.
Fleet Owner
Joined: Apr 2012
Posts: 27,307
Likes: 549
From: Spanaway
Odd thought. With all the heat and oil in the pit I bet they could of make some deep fried parts.
I am not into oil with my french fries.
Hotshot
Joined: Dec 2014
Posts: 17,833
Likes: 3,119
From: Jersey Shore
The oil that came out of the MH cover, in there for 75k, looked really good with no sludge in the bottom cavity like it did with the intitial oil after 50k. Most wear IMO occurs during initial break-in. My filling always was to the stock fill and level port.
I wouldn't be worried about a Mag Hytec cover. I just took advantage of a situation I’ve thought about doing for a decade. I was pretty close to just putting the steel cover back on.
I wouldn't be worried about a Mag Hytec cover. I just took advantage of a situation I’ve thought about doing for a decade. I was pretty close to just putting the steel cover back on.