rear differential cover rusted and leaking

Triacon · #1 03-13-2011, 05:46 AM

I have never done any work on a rear diff, but now's the time...
I saw some grease drips on the driveway, looked under the truck and see where it's coming from. What are the steps to replace the cover?

benny27 · #2 03-13-2011, 05:53 AM

http://www.fordrangerforum.com/how-s...5-rearend.html

Drexl · #3 03-13-2011, 07:15 AM

1) Take off old cover
2) Put new cover on

klinger86 · #4 03-13-2011, 07:18 AM

Quote:

Originally Posted by Drexl

1) Take off old cover
2) Put new cover on

make sure you clean the face of the diff before putting the new cover on to help prevent leaks...

brinker88 · #5 03-13-2011, 09:07 AM

Get yourself an oil pan or something simular.
Unbolt all bolts but top one. Just loosen top bolt.
Tap diff cover with deadblow hammer to break the seal
Drain oil and remove last bolt and cover. You will see your gears.
Scrape old gasket material off of diff and diff cover.
Get some RTV silicone and apply to diff. Smear it around so it covers diff cover mounting surface.
Wait approx. 5 minutes for it to start setting up.
Get diff cover and bolt on Loosely.
Tighten diff cover bolts in a cross pattern (like you are tightening lugs up on a wheel).
Remove diff cover plug and fill with gear oil.

ben10 · #6 03-13-2011, 09:13 AM

^x2 its a lot easier that it looks. Just make sure to clean all the surfaces so you get a good seal, use a gasket scraper and some brake cleaner if need be. Also while the cover is off look at all the components and make sure nothing is broken looking like chipped teeth and what not. Check the fluid you drained out for metal shavings. This can keep you ahead of the game knowing something is up with the diff.

brinker88 · #7 03-13-2011, 11:02 AM

I was scared as shit to do it my first time... I had help. Then After I saw how easy it was, I felt like an idiot

Twisty · #8 03-13-2011, 11:27 AM

I always use paper towels to wipe out as much oil as I can from inside the dif and then completely clean the cover inside and out.

Bwad · #9 03-13-2011, 12:21 PM

Quote:

Originally Posted by benny27

http://www.fordrangerforum.com/how-s...5-rearend.html

That is a great write up. Somebody give that guy a medal!

Blessed Ranger · #10 03-13-2011, 03:54 PM

If your cover is heavily rusted just make shore it didn't rust completly through. Living in the north for meny years I have seen this happen.

Triacon · #11 03-13-2011, 04:23 PM

Thanks for all the advice. I called a local shop today (Sunday) but they don't have new covers in stock, so i will probably just go to a Ford dealer tomorrow and get a new one. The original one is rusted thru.... There's a lot of rusty stuff on the underside of my Ranger. It's a 2000 4 x 4. Most of the time, I park it in my driveway but sometimes I park it on a gravel drive....... not too smart with that local, eh? Can I rake the gravel area and put a thick layer of poly type plastic, then spread the gravel over that for a less moisture prone parking spot? I suppose the gravel will eventually press through the plastic and I will be back to the same problem. Any suggestions other than plastic?

jack7481 · #12 03-13-2011, 05:40 PM

why not rope off a 10x10 area, dig down about 4' put a layer of gravel,sand smouth surface rebar tie together and pour a concrete pad to park on.

doyouquaxu · #13 03-13-2011, 05:47 PM

Quote:

Originally Posted by Bwad

That is a great write up. Somebody give that guy a medal!

Oldrang · #14 08-30-2011, 03:19 PM

Do you think I need an impact driver to get the bolts out? I have the same issue.

94mtx · #15 08-30-2011, 03:36 PM

I wouldn't use an impact in fear of breaking off one of the bolt heads... If anything, use a pneumatic wrench, not an impact.