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The rear diff cover on my 1996 F250 HD has rusted to the point that the lube is leaking through the cover. I ordered one from my local Ford dealer, they'll have it tomorrow for $37 plus tax. Do I need a gasket, or use silicone? The parts guy didn't know. He also didn't know what kind of lube to use. I have a factory limited slip. Any advice would be appreciated.
I presume you have the 10" rear. No fill plug on cover. On my '93 it used silicone seal. I used 75W90 Mobil 1 gear lube. YOu will need to add the limited slip gear lube additive. It goes in first before the gear lube. The fill plug is on the drivers side in front of the axle. Fill to the level of the fill opening. It takes something like 4 quarts.
While at the Ford parts store, buy two bottles of LS additive. I think this is only offered by Ford.
Cover is sealed with silicone. Would recommend shopping around for the silicone and gear lube. Ford parts prices may be quite a bit higher than someplace like Autozone.
The Mobil 1 that midlf mentioned is a synthetic lube. However, synthetics are not required.
The limited slip additive from Ford is different and must be added to MOST lubes whether they are synthetic or not. Note: a few synthetic lubes already contain LS additive.