@#$$%!* Aluminum Diff Cover Bolts!
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Lead Driver
Joined: Dec 2006
Posts: 7,092
Likes: 145
From: San Diego, CA
@#$$%!* Aluminum Diff Cover Bolts!
About a year ago I purchased a new '08 rear diff cover to replace the old steel one 
. The cover came with new hex-head aluminum bolts. I followed the instructions and torqued them down to spec (I don't remember the actual spec off the top of my head right now). Over the past year (more often recently) I pass by the rear of my truck and see a growing brown stain on the cover/housing. I climb under there with my trusty 1/2" hex head and snug down the bolts. I'm getting tired of these things backing out on me 
!
Has anybody used any steel bolts for the '08 rear diff cover? I don't need grade 8 bolts, but something other than these weak aluminum ones would be great (plus a little loc-tite won't hurt). I do a lot of off-roading and it seems that this is becoming more common. I would like to solve this problem before I end up really losing fluid besides just a mist!
. The cover came with new hex-head aluminum bolts. I followed the instructions and torqued them down to spec (I don't remember the actual spec off the top of my head right now). Over the past year (more often recently) I pass by the rear of my truck and see a growing brown stain on the cover/housing. I climb under there with my trusty 1/2" hex head and snug down the bolts. I'm getting tired of these things backing out on me !Has anybody used any steel bolts for the '08 rear diff cover? I don't need grade 8 bolts, but something other than these weak aluminum ones would be great (plus a little loc-tite won't hurt). I do a lot of off-roading and it seems that this is becoming more common. I would like to solve this problem before I end up really losing fluid besides just a mist!
Fleet Mechanic
Joined: Feb 2005
Posts: 1,797
Likes: 1
From: Northern Colorado
I don't think that I would have used the aluminum bolts to begin with. The rear diff goes through a heat/cool cycle every time you drive and this would surely cause bolt stretch. I think I would take one down to Fastenal or some other industrial fastener store and get some with allen heads that are black oxide... Grade 8 wouldn't hurt to eleminate the stretch factor.
Snowboard season cometh..
Joined: Jan 2006
Posts: 5,406
Likes: 1
From: Gulf Coast of Florida
I bought stainless bolts & washers from Home Depot when I put mine on almost 2 years ago. No problems with them backing out. I think my total cost for the bolts & washers was about $25 or so. Sounds like it's time for you to break the piggy bank. 
Post Fiend
Joined: Feb 2007
Posts: 14,541
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From: Dallas-Ft. Worth
x2, 'cept I got mine at Lowes. Been on a couple months now with no issues.
Fleet Mechanic
Joined: Feb 2005
Posts: 1,797
Likes: 1
From: Northern Colorado
That even sounds better than black oxide!
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Snowboard season cometh..
Joined: Jan 2006
Posts: 5,406
Likes: 1
From: Gulf Coast of Florida
The best part is that I had my diff cover powdercoated black!
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Posting Guru
Joined: Jul 2004
Posts: 1,777
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From: Buckingham, IA
Is it ok to use lock washers on aluminum or is it best to use just flat washers? Or both? A little lock tite or isn't that necessary? Lots of questions but I plan to do this some day and want to do it right the first time by learning from you guys. Maybe I better be careful here....
Postmaster
Joined: Jul 2004
Posts: 3,156
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From: Yuba City, CA.
Izzy is right, and this what I did. I should have been a little clearer in my post.
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Lead Driver
Joined: Dec 2006
Posts: 7,092
Likes: 145
From: San Diego, CA
Thanks. You read my mind. Reps sent!