Differential covers 101

[agesilaus]

PU Truck mag


That answered a lot of my questions about these covers. Extra large ones may not make a lot of sense because they disturb the oil flow in the housing.

[agesilaus]

I was interested to see the actual fluid level is a lot lower than I expected. I'm looking at changing fluid in the front transfer case and rear differential since my truck is over 100K now.

[SidecarFlip]

What I took away from the Banks video's so far is the shape of the cover in the center and the flush fit to the pumpkin casting promotes fluid flow up and back to the pinion whereas the cast covers impede the flow and the fluid has to make a sharp transition in addition. Other thing is, some of the aftermarket covers raise the fluid level from what the engineers set it at and that is no good either. Very impressive video's. I'm sure Gail is spending a lot of jack making them and really irritating makers like MagnHytek.

Only thing I wish was my stock cover (Corporate 10.25) has a drain plug in it. I have to pull the cover to drain mine, something I do every couple years. My front diff (Dana 60 full floater has a drain plug.

[filrupmark]

We have the stock cover with Mobil 1 Fluid and our Differential runs 165-170 degrees pulling our fiver .
I also am waiting on the final video. Very interesting.

[bobsallyh]

Over the years I've been a fan of looking at rear ends, but not finned aftermarket covers. Can someone tell me how long the rear differential in our 2003 Dodge dually is going to run with 242,000 miles on the clock with the plain old OEM cover towing a 40' fiver?

[dodge_guy]

Yes Banks did a lot of work on those videos to gives us the facts. I’m waiting for his Dyno testing to see what the temps do.
I went with the Ford Factory finned aluminum cover. $55 is way less than the aftermarket ones that create issues. I especially liked the one where he put the plexiglass cover on the aftermarket diff cover!

[Kennedycamper]

I never considered the fluid flow, but it makes sense. The upgraded Dodge cover is pretty much the same inside as the regular steel one, so fluid flow should be similar; however, it's aluminum & finned for better heat dissipation.

[agesilaus]

That is a very impressive couple of videos.

[ib516]

I don't think they have published the conclusion (temp readings) video in the series yet....I have been following it on YouTube.

[SidecarFlip]

I watched them all and I'm sticking with the OEM cover. The Banks expose' is quite enlightening. All the fancy covers provide no benefit except expensive bling.

Like Gal said. the OEM engineers know more about their axles than any aftermarket manufacturer. I have to agree with that statement 110%

[Kennedycamper]

I saw the Banks videos parts 1 & 2, but couldn't find the third part. I did upgrade my Dodge 3500 to the upgraded Dodge diff cover. Glad I didn't go with one of the others now.