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i've had a small weep around my lower rear dif. for quite some time, and never found it to be low on fluid...well this morning i decided to change out the fluid and take care of the leak once and for all...upon scraping of the outside of the cover (needed fresh paint) found a lot of rust under the paint..upon closer inspection i found it to have a lot of rust and verrryyy thin on the lower half of the cover..and you can see where the rust is coming thru to the inside..(99 150 4x 54k)
needless to say i picked up a new cover for 25 bucks....the new one had a lot of surface rust also...so if you have a wet behind you should try and check it out b-fore it gets real expensive..
oh yeah when you clean out the inside of the cover and you see dark spots in the metal/opposite the rust ,get a new cover...
mine was a 9.75 cover (tow package?)
standard is 8.8 i believe
good luck..
i have a 2001 screw with 130,000. took the cover off last month to change the oil. as you said, lots of deep rust on the cover. i was thinking mine was heavily rusted on 1/2 and not the other. seems like the rust was on top half above the oil level line. . burnt the paint off, it appeared. dont know why. cleaned and repainted and plan to monitor what it does the next year.
mine rotted out on the bottom of the cover..under the paint...i'll be good for another 50k with the new cover,,i hope just cant get this dang paint to dry ..lol