Rear Differential Cover Rust Problem

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Apr 19, 2009 | 11:29 AM

Hawks250

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Rear Differential Cover Rust Problem

Hello All-

I'm new here and I searched first for a thread on this topic and came up empty.

I have an '06 F-250 4X4 Crew Cab Lariat w/ a 5.4 engine. While doing a little spring cleaning I noticed the rear diff cover was pretty rusty. I crawled under with wire brush and anti-rust paint in hand to clean it up. The cover is severely rusted and peeling off in layers. It is beyond just cleaning and needs to be replaced. This truck only has 51K miles. Has anyone else experienced this and does anyone know if this is an inherent problem? Does Ford have a silent warranty covering this or am I on my own? Thanks in advance for any info provided.

Apr 19, 2009 | 11:43 AM

1975StroppeBaja

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From: WV

This is a pretty common problem. A lot of folks replace the stock cover with a 2008+ aluminum finned cover. They're not too spendy and are a direct replacement (will need longer bolts though!).

Here's a few good threads on the subject...
https://www.ford-trucks.com/forums/7...ous-years.html

https://www.ford-trucks.com/forums/7...ing-again.html

Otherwise there are a bunch of aftermarket covers available. The Mag Hytec cover is pretty popular.

Good luck!

Apr 19, 2009 | 11:44 AM

juneau76

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Welcome to FTE! That is a common problem for us northerners dealing with salt in the winter. I don't believe it is a warranty thing. You can get a new aluminum cover from an '08 and that will solve the rust issue since you are buying a new one anyhow. Get in touch with Ed (FTE/PARTS-GUY) and he will take care of you. His site is ftepartsguy.com.

Apr 19, 2009 | 11:45 AM

melon350

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It is a common problem. Probably the best thing to do is get an aluminum cover for an 08' and never worry about it again. If you go this route I have extra coated bolts and washers I got from mcmaster when I did mine I'll sell you cheap, then you just get the cover from the dealer or there are vendors on here that will give you a great price.

Apr 19, 2009 | 11:46 AM

melon350

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A bunch of us typing at the same time on that one!

Apr 19, 2009 | 11:49 AM

juneau76

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Hey melon350, what are the part numbers for the bolts you got from mcmaster? I haven't decided what I'm going to do for mine yet, so I'll let someone else take the one's you've got.

Apr 19, 2009 | 11:58 AM

melon350

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I found the part numbers in someone elses thread on the 08' covers. They come in big amounts though, I think the bolt come in 25 and the washers in 50, cost was around $20-$25 i think.