Diff cover- compatible with the Explorer??

[Turdle]

I didn't want to hijack this thread and hadn't gotten my cover done back in October, but I want to chime in with the "ballin on a budget" option of using an IRS 8.8 cover from a 3rd or 4th gen. It's certainly been covered before and on other forums: basically pull the cover at a JY, lop of the mounting ears for the IRS, and blend what's left however you like.

$20 for the cover, a couple hours with a port-a-band and die grinder, Rust-Oleum semigloss, and another 30 min with a cartridge roll nets you this:
View attachment 459665

I'm mostly excited just to have a drain hole, but a thicker cast cover with cooling fins can't hurt either.

Is that cast iron or aluminum?
I like the location of fill, and, drain is so large it should allow visual inspection to a degree.

 

[97Sandbox]

That's the biggest drain plug I've ever seen on a diff cover. Must be meant for fast NASCAR style pit work. LOL

Yeah, it takes a 3/4 square drive. Glad I have a 1/2 to 3/4 adapter because I have no use for 3/4 drive anything in my current fleet.

Is that cast iron or aluminum?
I like the location of fill, and, drain is so large it should allow visual inspection to a degree.

Cast aluminum. This is the stock differential cover for '02-'10 explorer, just with the IRS mounting ears cut off and the edges smoothed out. The fill plug may even be at the same height as our solid axle 8.8 -- I'll have to look at that when I eventually put this cover on my Sport.

 

[410Fortune]

It’s so the metal bits flow out too!