The other day I was driving down the road when I heard a loud clank so I pulled over to check out what it was, I got out of the truck and went to the rear and realized I had a hole through my differential cover and was leaking fluid out of the rear.



I had my friend pick it up with his trailer and bring it to my house so the next morning I could open the diff. and see what happened. Upon opening it:




The gears were fine but there was two big screws that came out of the ring gear and I guess backed themselfs out somehow and the gears threw them against the diff cover causing it to bust a hole and then fell to the bottom of the diff.

So I took it to a mechanic to have it looked at and they fixed the problem but when they went to re-fill the differential they said they couldnt get he fill plug out...so they welded the hole in the rear and drilled another hole and plugged it up when they got done filling it.

My question is, since the rear differential now looks like **** would I be able to buy a new differential cover and then fill the diff up using the ABS sensor hole? I'm stuck on what to do but I know I need a new cover because it looks like garbage right now.

 

Maghytec.com.

 

I've been trying to sell it for the past month and then this happened so I really don't want to dump money into it more than I already have, I was thinking about a cheap cover from jeggs for like 30 bucks, or just putting bedliner over the weld mark?

 

Because the weld is sturdy and the plug isnt going anywhere , its in there pretty damn well and won't budge, I just dont like how it doesnt look clean

 

Black spray paint. =)

 

Just tried the black spray paint undercoating idea....it looks better...but theres still a huge chunk sticking out from where it is welded shut....thinking I might just buy a new cover and try the ABS sensor filling up spot "

 

Good thinkin on your part.

Great skills lol. Mechanic must be accustom to not having that much to work with lol.

BTW - Covers are anywhere from 8 - 300 bucks apiece. Just find a cheapo on ebay or something.

 

Well he trys to "save people money as much as possible" so he welded the hole instead of buying a new one and charging me for that, I can understand that and I'm not mad at all, but I know theres no way in hell I'm gonna sell it with a huge tumor looking weld coming out of my differential, even I myself would be like hell no I'm not buying this truck after seeing that, to many thoughts would go through my head.

 

Right! I'd just pick one up real quick. Like I said, they can found relativly cheap if you look around.

Like here for instance -

http://www.ebay.com/sch/i.html?_trks...cover&_sacat=0

 

BTW - You CAN use a gasket with those. BUT IMO and Fords, -Permatex "Black" is the better route.

 

How you apply that. Run a bead around the casing, wait a 1/2 hour for partial set-up, install cover snug, torque to spec in the morning.

I have to say, I've torqued them home after the 1/2 set-up time and haven't had a problem.

That P-Black is great stuff!

 

So your saying don't use a gasket at all? Just put the silicone around the differential cover (in between the holes) and then put it on?

 

thats what i did and i have no leaks.

i have a stock diff cover you can have, just pay shipping.

 

I never heard of not using a gasket, but I'll be more than happy to buy the cover off of you, assuming it has no holes in it or weld marks

 

yeah its in pretty good shape. i just replaced it with a TA diff cover. theres nothing wrong with it.