Like many people the rear diff cover on my 2006 FX4 is rusty and flaking. I am not worried about anything in terms of function, but it looks like complete crap. Has anyone painted it while still on the truck, and if so what did you do about the bolts? I went by the recycle place to see if I could buy another cover to paint off the truck but they did not have any, and I won't buy a finned one.

p.s. I plan to use POR 15 as I already have a can

 

Just curious, why don't you want a finned cover?

 

Its not that I don't like them, its just not an investment I want to make right now.

 

sand blast it and powder coat it

 

That'd be the best option. The POR15 would be a good 2nd though, not to mention cheaper. Just pull the differential cover, drain the oil, clean the cover, sand it with 320, clean it again, and paint it with POR15. The differential fluid is 75w-140 by the way.

PS: If you do ever get a new cover, get the Mag Hytec. It's got a dipstick, drain plug on the bottom, as well as two magnets to pick up any metal shavings.

 

X2, And if you can find a grinder with a wire wheel to clean it up, much the better. Besides that, you get a fresh filling of fluid. Cost= Paint, fluid and a gasket or black RTV, clean the mateing serface clean and don't throw away the tags bolted on they may come handy in the future.

 

Flat black Tremclad

I did mine the beginning of last winter (not this winter), and from underneath the truck looks like an 08, not an 05.

I didn't even worry about the small amount of pitting that had already occured. I just Tremcladed right over top (made sure it was clean first, of course) the small pitted rust marks that were already there. The bolts were already black, so I just went right over them as well.

It still looks great, and it was so easy to do!

 

Any pics?

 

No pics of the diff specifically but trust me, it looks clean, and that's almost after two complete winters. Winter isn't over in these parts yet.
People are surprised when I tell them it's an 05, mind you, the mileage is still low on it (50 k km's).

I touched up any spots that were already flat black like the frame, axle, etc etc.

 

wow.. i just bout some black spray paint, went under my truck and started painting.. still looks good..

 

I realize that Tremclad is flat black, but with a spray on tire dressing (foam) will it hold a shine? Also, has anyone applied it with a brush for those hard to reach/mask places?

 

If you want it to shine, then get a glossy black can of spray-on rust paint

 

when i change my oil, i roll around under my truck with a can or two of flat black paint to keep everything looking new. Its not a habit to get in.

 

I had my truck undercoated after I installed the lift, so the rearend was sprayed at that time.

Ruberized undercoating is an idea.