Looks like Banks Engineering finally released their new rear diff cover. Pretty amazing video. Limited availability right now...

 

Neat video.

 

As a patent attorney for over 20 years, I can tell you getting a patent is really no big deal. And the gilded patent that he shows you must be from the 1800s, because they look nothing like that now.

The Banks numbers in this video look better that in a previous video that I saw. Still, for the average person, not a lot of bang for your buck.

 

Finally some more Imagineering details with data & interesting stuff for me, as I'd not thought about this for decades, being busy with other daily details that required immediate attention.

Seems to me what they have designed here is a differential enhancement, that would be worthy of consideration for folks operating in & lugging & tugging Big loads, for Long times, at Highway/Interstate speed, in Hot weather. I'm thinking like long haul OTR folks on I-10, or I-40 lugging & tugging over the great divide in summer & running the open flats at 100mph in a convoy. Their differential lube would likely appreciate all the extra cooling it could get under those conditions

Folks operating in Cold country, probably wouldn't want to run this puppy in Winter, as it would likely Overcool the differential lube in really cold Winter conditions. Can you imagine how long it would take at highway speeds, with all this Extra cooling, for the lube to warm up enough to begin to do a proper lube job in sub zero Artic temps!!!! Think about how the really Cold lube would look after it was aerated in sub zero temps & how much air would be entrapped in & how long we'd have to drive before the lube warmed up enough so those air bubbles could begin to pop & come out of the lube. Aerated fluid doesn't lube worth a flip & it doesn't help with oxidation either. SO, imo cold country operators would be wise to Think through whats going on inside their differentials in Cold weather, before jumping on a extra cooling in Winter bandwagon.

 

I'm trying to recall, if ever, someone suffered catastrophic failure from using any other brand's differential cover. I just can't remember at all, if someone posted with, "AFE diff cover, gear box blew up!"

 

I have never heard of anyone blowing an engine, let alone blowing an engine because they used cheapo dino oil.

And yet, walk down the oil aisle at Wally-World. Dozens of types of syn and semi-syn oil.

Marketing WORKS!.

 

I love the science behind the video. Facts and data trump all. But, what problem is he solving? It’s definitely not “why did a bunch of guys detonated their rear diff because they were hauling heavy”. He set out to determine if the larger volume aftermarket covers work. I think he clearly proved they don’t deliver on any of their promises. They don’t cool better, they don’t lube better, mo’ oil is not mo’ better and they foam the oil...no bueno.

Now, if you ask does this solve a big problem? No, I don’t think it does. If you’re overheating your diff oil, then this is good stuff. But Banks definitely never addressed the ideal operating temp of rear diff oil and if his new system possibly over-cools the fluid. So at the end of the day, it will mostly be about putting shinny cool stuff on your truck...

So, I guess I’m in agreement with you guys. I was excited about a Banks cover, but mainly because I’d like to have a cover with a drain.

 

I think that most aftermarket covers have a drain.

 

Just a thought......a diff cooler was made for Mustangs. Nobody considered a diff cooler for a truck?

 

Well in the video he did say they have Improved aeration a great deal, optimized fluid dynamics to aid flow forward to the carrier, pinion & axle bearings, so to get a good lube & cooling job done on them, so all his effort was more than just external "Bling".
I don't work my Ranger that hard, nor for that long, in our moderate climate, that I'd likely Need the extra cooling. BUT if I lived in the southern USA, or other like world Hot temp areas, I'd sure consider installing one on a hard worked vehicle.
If you just want to add Bling, well it has plenty of that too & doesn't cost any more than the flat back covers. It has a sight glass so we can see when we have the fluid at the proper fill level & can easily see it for a check, so we don't have to remove a fill plug & stick a finger in to feel for a About right fill level. Has easy to get at magnetic fill & drain plugs.
A Plus is its internal fluid dynamics has been given some Serious Flow, Heat & Aeration attention, so it doesn't over aerate the fluid like the flat back covers & does get the heat out of the fluid. We want to see & keep the fluid Operating temps around the 200*F range & it seems to do that.
The 300*F temps they saw isn't good for lube, bearings, seals, or gaskets, so again, when lugging, tugging Heavy loads at High speeds, for Long times in Hot climates give this puppy & a good quality synthetic fluid some serious consideration.
If you live where you see artic cold in Winter, you don't likely need the cooling, but you could likely make good use of a quality 75W-XX synthetic fluid that would be way less vicious at cold temps, so less aeration at start & warm up times, while lugging & tugging at highway speeds & the rear running gear would likely appreciate that in artic cold temps.
More thoughts for consideration.

 

You are assuming, of course, that the stock differential cover is inadequate.

Assuming that the engineers at Dana, American Axle, etc., are competent, then the stock set up should provide adequate cooling, fluid flow and protection against aeration.

You really do not need to fix something that is not broken.

 

80,000 miles using a Mag Hytec cover and no failure.

 

That's encouraging to hear. The clunking sounds that the modified plastic window Hytech flat back cover began making at 50 mph in the video, sure were ominous sounding & he said all hell broke loose at 80, so I'd sure be concerned about whats going on inside the differential with the fluid dynamics of a inside "flatback": cover.

 

The only reason I would upgrade my covers is if it's on a vehicle that is used primarily for off-road. A thicker steel cover protects the the internals from rocks logs and other obstacles, and it stiffens up the housing. I have heavy duty Solid covers on my Jeep for that reason. On a vehicle that's mostly use on road and only sees occasional off roading the stock covers are fine. The Banks cover has a lip that hangs down past the cover that can easily catch on something and peel that aluminum cover right off, it also does little to protect the gears or stiffen up the housing anymore than the stock cover does. I wouldn't put that cover on anything but a pavement princess or a show truck.

 

Dude. I created an account just to reply to this comment.
If you watch the video instead of concern trolling, you will see that Banks initially began investigating aftermarket diff covers because his employees were running aftermarket units and his initial assumption was that surely American Axle/vehicle manufacturers made a more than adequate cover from the factory . He found that he was correct in his assumption in that oil flow was much improved when switching from aftermarket back to stock covers. This is due to the aftermarket covers having heavily obstructed/recessed areas in the fluids path heavily blocking it’s travel around the ring gear causing aeration and heat.
The factory unit doesn’t do this friction/work on the oil because of its rounded shape. All he did was improve upon the FACTORY design and made it better by adding oiling channels to help give it a more direct path to carrier bearings (all proven with testing using clear acrylic mock covers). The bottom has ram air induction that curves up to the fins and keeps temps down. It’s got a sight hole for fluid level. It’s a machined surface with an o-ring. It’s thorough engineering. Give Gale Banks his due diligence and watch his video before making ignorant comments. Most manufacturers in the aftermarket aren’t transparent like this and we should appreciate the ones who are like Banks. They couldn’t hold a candle to his name because they sell crap and they know it.