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Is the stock rear diff cover Plastic (or otherwise not metal) on a 1991 ranger? I was out wheeling and discovered I had chipped a piece off. luckily it isn't leaking, but Im making a trip to the local you-pull-it to replace that.
I believe it's alloy. If your going to be doing a lot of wheeling, you may want to concider an aftermarket steel cover. Ford sells them through SVO or ford racing as do other off/road suplires.
TRS (the ranger station) sells one with their logo on it, it's made out of steel, is enlarged for a greater fluid capacity, and has a built in drain plug for more conveinient service. I'm not plugging TRS, just pointing out a good product. I think the pan may depend on which differential you have, both of my 7.5's have a stamped steel pan, never really looked at my old exploder 8.8'. I'd say get a steel pan if you don't have one, a larger volume pan can take a dent or two without hitting the ring gear, which might be worth considering if you wheel at all.
Yeah, the aftermarket steel covers do hold more fluid, have a drain plug, some have enforced ribs with enforced griddle bolts. I thought the stocker should be sttel myself, but I never heard of steel chipping, so I assume it must be some kind of alloy. I know my 04 was steel, cause I had it off when I had my tru-trac installed.
ford_4.0, you're right about the cover being plastic. The diff cover on my 91 is plastic like that also. I found that out last summer when I was changing the gear lube and noted some gouge marks from the bolts that hold it on. Then when I cleaned it in solvent I could see the fibers in the cover. It should be replaced with a metal cover since you're doing some off roading.