Leaking differential Ford E450

[Juzaxadar]

I found a slight leak in the front seal of the differential while I was checking for issues. I tried to get the fill plug out to top it off, and it's rusted shut. In fact, the 1/2" ratchet wouldn't even fit. No matter what I did I couldn't make it work.
picture:


After checking on prices to replace the seal I decided to replace the differential cover which includes a new fill plug. It'll be cheaper to just keep the fluid up.

Interesting stuff: Ford could not ID the differential based on the VIN or the door tag (axle = 81). The "non-rusting" aluminum tag on the differential itself was unreadable. I ended up spending a 15 uncomfortable minutes with my phone taking video under the RV to find some clue that this is a Dana 80 differential.

I ordered the cover and hopefully will get it next week in order to see if it fits.

[Juzaxadar]

The bolts were actually solid underneath, which I thought they might be, but yeah, it would be a nightmare. I got it all snugged up and torqued. I could not find specific torque specs so I went with 25lb, which to me feels maybe slightly more than the old bolts. I have to run to Harbor Freight this evening and pick up one of their cheap transfer pumps so I can get the oil into the differential.

[T18skyguy]

Thank god those bolts came off without breaking. That would be a real nightmare. I have an 03 E 350 and the cover is just as rusty. It's not leaky and so far am leaving it alone.

[Juzaxadar]

I got the cover off today. The bolts came out surprisingly easy.
I'm including a link to the imgur album instead of linking 10 pictures.
https://imgur.com/a/NLhbX9S

I ordered some new bolts and will pick them up tomorrow and put it back together.

[Juzaxadar]

I found this on order from advance auto for $37 + shipping. It appears to be the same size so it's a dana 80.
https://imgur.com/VnoIjNH

So I soaked the bolts and will try to crack this puppy tomorrow. The bolts are rusty as heck, so I may replace them. Hopefully nothing breaks.

[Juzaxadar]

I found this on order from advance auto for $37 + shipping. it appears to be the same size so it's a dana 80.

[Juzaxadar]

I found this on order from advance auto for $37 + shipping. it appears to be the same size so it's a dana 80.

[77rollalong]

getting the diff plug out, I just use the oxy-act torch and head up around the outside of the plug and hammer in a 1/2 inch extension into the drain plug and hit it with the impact gun. the fill plug is a regular pipe plug, get at most hardware stores.

[Juzaxadar]

There are only about 69k miles on it. The front seal slight leak is the only reason... but that's life. I will take pics for sure. I'll take the cover off either way, and if the new one is the wrong size I'll have the old one off and maybe with some room to work and pb blaster I can get that old fill plug out. If that happens I would need to find a new one, but I have not found a new fill plug.

[twodownzero]

SidecarFlip wrote:

time2roll wrote:
Back in the day I would clean the plug with an air chisel and then hit it with an impact gun.

Images of Dana covers

Same here but I give them a shot of PB or ATF and acetone mix, let it sit a day and crank it out with a 3/8" square drive extension and if it's tight a little persuasion with an impact always does the trick.

I can look at a 3rd member and tell what it is but that comes from experience. Fords tend to use Dana axles in heavy application or corporate axles in lighter duty apps, like F250 and 350 pickup trucks. FCA uses American axle and GM uses both American Axle and corporte stuff depending on model.

Instead of buying a new stock cover, I would have bought something like a Mag-HyTec and put that on. or just replaced the stock one with a new gasket and some sealant.

AAM is just a spinoff of GM corporate axles from back in the day. Yes they are shared with Ram now, but they are mostly just GM style axles.

Op, get yourself some pb blaster.

[mchero]

How many miles are on that differential?
Shoot us some PICS when you replace the cover.

Thanks for the post.

[Juzaxadar]

I thought 3/8 as well believe me. But it's loosy-goosy. The 1/2 would fit if it weren't for the rust. I tried my dremel to clean out and it's almost good enough but not deep enough, and the hole started getting tweaked/stripped. It's also difficult because the rear sway bar and the gas tank are in the way so I have about 3" clearance which is just enough to get the dremel and/or a screwdriver into 2 of the 4 bottom corners and try to clean/square them off. The third one I just can't get to.

As far as IDing, I looked at the door code (81) and called Ford and gave them my VIN. They could not ID it. So I stuck my phone with video on above the differential and found a spot where it has "80" on it. Lots of web searching and that's what I came up with. That plus the measurements, bolt holes and counts, etc. The chassis owners manual references Dana 60, 70, or 80.

A new cover shipped is less than $50 shipped, and I can return it minus the $7 shipping if I'm wrong. I have to do that, but taking it anywhere and doing anything will cost me more than $7.

Mine looks exactly like all of those Dana 80s. They all look the same to me. https://www.randysworldwide.com/differential-identification-dana/

[SidecarFlip]

time2roll wrote:
Back in the day I would clean the plug with an air chisel and then hit it with an impact gun.

Images of Dana covers

Same here but I give them a shot of PB or ATF and acetone mix, let it sit a day and crank it out with a 3/8" square drive extension and if it's tight a little persuasion with an impact always does the trick.

I can look at a 3rd member and tell what it is but that comes from experience. Fords tend to use Dana axles in heavy application or corporate axles in lighter duty apps, like F250 and 350 pickup trucks. FCA uses American axle and GM uses both American Axle and corporte stuff depending on model.

Instead of buying a new stock cover, I would have bought something like a Mag-HyTec and put that on. or just replaced the stock one with a new gasket and some sealant.

[Cummins12V98]

"All the fill plugs I've seen with square drives are 3/8 inch."

You beat me to it!

[pauldub]

My '03 E-450 has a Dana D70-HD diff. I'll bet yours is the same and the D80 cover may not fit.