Excessive Rust on Diff Cover
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Junior User
Joined: Nov 2004
Posts: 58
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From: Kure Beach, NC
Excessive Rust on Diff Cover
On my 2000 4wd Ex, I seem to have excessive rust on my rear differential cover. There are big chunks of rust/metal falling off. Has anybody experienced this?
Elder User
Joined: Jan 2004
Posts: 561
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From: houston
Have you done any heavy towing? I read an article once that that was caused by excessive heat. I have the same thing on mine, 97 F-250 4x4. I've towed heavy a couple of times, but can't remember if it was rusty b4 the towing. I check it every now and then for leaks but nothing. When it goes, I'll get one of those hi-dollar extra capacity ones. Good luck.
Freshman User
Joined: Dec 2004
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Replaced mine yesterday actually. Problem...lousy steel (very common problem in many things..rotors, ball-joints etc., these days- not just Ford either).
Good News- New cover is cheap enough..like eighteen bucks (comes bare metal- use a good rust-inhibitor paint)
Bad News - Synthetic fluid you will dump is about $20 a quart and you'll need 4.
Hope this helps...good luck!
Good News- New cover is cheap enough..like eighteen bucks (comes bare metal- use a good rust-inhibitor paint)
Bad News - Synthetic fluid you will dump is about $20 a quart and you'll need 4.
Hope this helps...good luck!
Junior User
Joined: Nov 2004
Posts: 54
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Just take a wire brush to it, then apply a good rust inhibitor primer and a top coat in the color of your choice ... yellow with a smiley face?
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Posting Guru
Joined: Nov 2002
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From: Texas
Well, Mag-Hytec makes an excellent oversize cover. My 350 had the peeling paint and I just replaced it with the magnegsium cover. Doubles the capacity, fills from the top, has a drain and a place for a temp sender. Kinda pricey, but the comments on it--priceless. Mag-Hytec.com
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New User
Joined: Jan 2005
Posts: 19
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From: Long Island, NY
I had a 99 F250 PSD and the cover too was really! rusted. I live on Long Island, NY, not very close to the water, and have fairly mild winters, thus little road salt. Now I have a 2000 Excursion PSD (needed room for growing kids, miss my pickup!......should have bought rain gear for the kids and put them in the back), it too has a really rusted cover. Looks as if I'll have to change it. Must be cheapo steel. I have a few other vehicles, all older, and none of them look like these.
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Junior User
Joined: Nov 2004
Posts: 58
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From: Kure Beach, NC
Thanks for all the feedback. I found numerous places on the web to find new replacement diff covers. They range in price from $30 on Ebay to $230 for the MAG-HYTEC. Looks like its pretty easy to change. Now I just need to choose.