Front Differential Cover

[Mounty 09]

Well my front diff is leaking at the cover case seal. So I am going to drop the diff next week and reseal it up.

My question is does anybody make a diff cover with a drain plug for when I have to change fluid again? Looked a little but am worried about clearance. Has anybody put one on and which one did you go with?

Thanks

 

[swetrid]

I doubt that the cover seal is leaking because it is silicone. The pinion seal or vent tube concerns are the cause of most leaks. Never seen the cover leak in 16 years as ford tech unless someone already was in there.

 

[1AJeremyD]

I haven't see a lower mounted diff plug on a ford before. You might be able to make one on the new one if you are good enough using a drill and a tap.

 

[Mounty 09]

I doubt that the cover seal is leaking because it is silicone. The pinion seal or vent tube concerns are the cause of most leaks. Never seen the cover leak in 16 years as ford tech unless someone already was in there.

If you want me to take a picture I will. It is leaking at the cover seal.

1AJeremyD I was looking at some aftermarket ones but was worried about clearance. I think I'm just going to stick with what I have. Hopefully next time I have to change the fluid it will be time for a SAS.
http://www.summitracing.com/parts/SUM-730501/

 

[Fifty150]

My car has a Dana 35 in the front. If you "google" Dana 35 covers, you should find tons of them. Start with Summit Racing. A lot of those differential covers are about the same size as the OEM.

 

[Fifty150]

 

[CDW6212R]

View attachment 387314

This is not a cover that will fit the Explorer front diff, it's a regular D35 cover which uses a different bolt pattern. The Explorer front diff, uses an EZGO golf cart cover bolt pattern.

I looked at the cover above hard until I found it cannot work. I like to find one similar to this pictured, but it obviously has to match the Explorer bolt pattern. I searched through threads to see what other had done. So far nobody found anything to work. I might relent and weld on a bung to the stock steel pan, to add a drain plug. A nice polished AL cover would have been easier.

Oh well, and RickOTR posted EZGO15054G1 as a gasket that will fit our front diff.

 

[410Fortune]

Fitting a wrench in there to pull the new drain plug could get interesting it would have to be placed just right

I wish I could drain them… it would make life easier. There is no way to suck the fluid out either a hose just won’t go in there and then down to grab fluid

I always end up just dripping the diff to drain it. It’s not terrible you can remove the cv axles and have the diff on the ground in about 30 minutes, tip it up and drain. Plug would be so much better

 

[CDW6212R]

If I get to doing one, it'll point straight down. I envision a metal bung for a common plug, and weld it to the cover where the ring gear is not.

For my work I would have changed the gear oil every year, but regular usage only needs it maybe every 100k. For off road where you might think of water getting in, it would be great to change it whenever just to be sure.

 

[BrooklynBay]

 

[CDW6212R]

The problem as Jamie pointed out is that the fill plug is right next to the internal guts, which stop any hose from reaching down below any distance. The fluid needs to come from the bottom, and the fill plug is a few inches above that.

The EZGO golf carts have a cover that may physically bolt onto our carrier housing, and they have a large rubber fill plug. But it's on the very front, so you'd have to bore a large hole all the way through the frame cross member, and the steering rack too.

 

[BrooklynBay]

On my van, I'm able to remove the speed sensor on the top to add or draw out fluid. Is his differential not set up the same way with a top mounted speed sensor?

 

[410Fortune]

No speed sensor in d35 ifs
Just a 90 degree vent tube . Hmmmm

I have one sitting right here

I also have one I’d like to change the fluid on. The vent tube can be removed but once you do they never seem to fit back the same

This is what we are dealing with once installed

Sucking fluid with a tube from the vent location. May or
May not be possible
I will report back lol

It’s tight but there should be room for a plug we can get to

 

[BrooklynBay]

Is the angled vent tube connected with a rubber grommet or does the fitting have its own built in grommet? Dorman has a lot of grommets in many sizes.

 

[BrooklynBay]

I known that it's more work but what about tapping a thread for a screw in fitting which is easily removable?

 

[CDW6212R]

The place to put a drain plug is just to the left of the lower center bolt, where the cover is flat going upwards. The ring gear is behind the right side that protrudes. I can see a cross cut steel pipe sectioned, an angled cut pipe, welded to that flat of the cover right at the bottom left of center. Weld a bung into that pipe opening, pointing the threaded plug down. Weld it carefully to seal it right, clean up the weld seams, paint it and bingo, a nice drain plug easy to reach right at the bottom behind the frame.

How's this spot look to place the drain plug?

 

[wollimann]

Why so complicated, if the diff is on your work bench, drill a 8mm hole inside the diff housing into the thread of the lower right bolt. For draining only loose the bolt. Never had a leaky front diff cover.

 

[410Fortune]

I was thinking the same thing connect the drain to the bolt hole

 

[CDW6212R]

Now that's an excellent idea and answer. That's worthy of an award, where's Rick?