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Diff cover rust

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Old Jul 22, 2019 | 07:35 AM
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Diff cover rust

See the pic below. That’s not a leaking gasket, that’s gear oil literally sweating through pin hole rust perforations in the diff cover. Kinda awesome and gross.



I got super lucky and none of the diff cover bolts snapped. Clean replacement.


 
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Old Jul 23, 2019 | 07:39 AM
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Nice job

There was an aluminum diff cover that Ford put on the later Superduty, that was pretty cheap direct from Ford, in case anyone is wondering.

I notice you used blue RTV - does it smell like dirt? Or silicone? I did't think blue silicone will hold up to gear lube...
 
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Old Jul 25, 2019 | 08:42 AM
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None of the bolts broke off…go buy a lottery ticket! . I hate that RTV, I use the LubeLocker gaskets, clean easy installation and reusable.
 
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Old Jul 25, 2019 | 01:13 PM
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How much they charge you for the cover? My 03 was getting close to looking like that, but I sanded it and painted it and I climb under once a year and wipe it down then throw some more paint on it, at this point I would assume paint is the only thing hold the gear oil inside...LOL
 
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Old Jul 25, 2019 | 09:28 PM
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Aluminum cover direct from Ford is less than 60 bucks
 
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Old Jul 26, 2019 | 11:52 AM
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Is also supposed to dissipate heat better. I also went Lube-locker
 
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Old Jul 26, 2019 | 02:22 PM
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Originally Posted by Chuck-B
.... Is also supposed to dissipate heat better. I also went Lube-locker
Ford started installing these in 2008, they must have had a good reason to spend the money.
I also went with a Lube-Locker and it needs longer bolts.
While it was off I drilled/tapped an 1/8" pipe hole for a drain.
I know it all won't drain out, but at least there isn't a big splash of lube when the cover releases.

 
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Old Jul 27, 2019 | 08:17 AM
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Originally Posted by Chuck-B
Is also supposed to dissipate heat better.
Absolutely with the next best one being black steel. The aluminum one would concern me only if doing a lot of off-roading. It sticks out more, isn't smooth, and it's not as strong as the steel cover.
 
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Old Jul 27, 2019 | 08:35 AM
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R&T, did you paint yours? Nice job on the drain plug, I don't have the nads to try that. I went with the ARP 612-1250 5/16-18 x 1.250 12pt SS bolts. A little pricey but stainless and the bolt being 12 point adds a little bling for those that want to get on their knees and take a look.
 
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Old Jul 27, 2019 | 10:10 AM
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Did you guys look at the youtube videos banks made about all the fancy covers ?
 
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Old Jul 27, 2019 | 12:39 PM
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Originally Posted by geekwithoutacause
Did you guys look at the youtube videos banks made about all the fancy covers ?
Yes, and since the inside of the Ford aluminum one is identical to the Ford steel one that's been used since Ford started using the sterling rear axle I'm sure it's safe to use
 
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Old Jul 27, 2019 | 03:02 PM
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Originally Posted by SuperDutyScaler
Yes, and since the inside of the Ford aluminum one is identical to the Ford steel one that's been used since Ford started using the sterling rear axle I'm sure it's safe to use
Cool. I just wish it had a drain plug.
 
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Old Jul 27, 2019 | 04:19 PM
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Originally Posted by Chuck-B
R&T, did you paint yours? .... I went with the ARP 612-1250 5/16-18 x 1.250 12pt SS bolts. A little pricey but stainless and the bolt being 12 point adds a little bling for those that want to get on their knees and take a look.
Yes, I painted it with black engine enamel.
Those 12pt SS bolts are nice, but even on my knees I can only see the bottom 2" of the cover, it's a 2wd Excur and there's a 44 gal gas tank in the way.
 
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