Differential cover leaking - Ford Powerstroke Diesel Forum
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post #1 of 13 Old 01-05-2013, 10:42 AM Thread Starter
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Differential cover leaking

I have to change the gasket and get the leak stopped, does anyone have any words of wisdom on doing the job right? Things to look for while the cover is off? I hate to do things twice!
Thanks!
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post #2 of 13 Old 01-05-2013, 11:22 AM
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Use the grey Ford sealent or Permatex 85084, clean reseal let set 24 hours if possible then add fluid and Ford additive if its a posi. I never get leaks again.
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post #3 of 13 Old 01-05-2013, 11:30 AM
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Also, check cover itself. Some of them rust. I pulled mine, sanded, repainted

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post #4 of 13 Old 01-05-2013, 01:26 PM
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Or use it as a excuse to upgrade to a 08 aluminum cover and never worry about it rusting again.

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post #5 of 13 Old 01-05-2013, 04:09 PM Thread Starter
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I'll have to check on that cover...thanks for the advice, I hope to have it all buttoned up Wednesday.

2003 7.3L
NRA Sticker on back window
Missing muffler mod
Potential by Ford...
6.0 Trans cooler now installed.


“Democracy is two wolves and a lamb voting on what to have for lunch.
Liberty is a well-armed lamb contesting the vote.” Ben Franklin, 1759
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post #6 of 13 Old 01-05-2013, 06:45 PM
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Get the 2008 finned aluminum cover. Clean the surface of the differential really good, use "The Right Stuff" from Permatex to put in the groove of the cover, then install the cover.

Let it sit for a few hours before filling with oil so the silicone can cure a little bit.

I battled a leak for months before doing it this way. I have been leak free for about 6 months now.

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post #7 of 13 Old 01-09-2013, 07:26 AM Thread Starter
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OK, have the cover back in place, waiting for a little cure time before I fill it up...does anyone put pipe dope or some sort of tape or sealant on the fill plug? It looks like it had something orange on it when I took it off...I cleaned the threads and am thinking while I wait.
Thanks,
Mike.

2003 7.3L
NRA Sticker on back window
Missing muffler mod
Potential by Ford...
6.0 Trans cooler now installed.


“Democracy is two wolves and a lamb voting on what to have for lunch.
Liberty is a well-armed lamb contesting the vote.” Ben Franklin, 1759
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post #8 of 13 Old 01-09-2013, 08:24 AM
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I use teflon tape.

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post #9 of 13 Old 01-09-2013, 11:17 AM
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Quote:
Originally Posted by mjkten View Post
OK, have the cover back in place, waiting for a little cure time before I fill it up...does anyone put pipe dope or some sort of tape or sealant on the fill plug? It looks like it had something orange on it when I took it off...I cleaned the threads and am thinking while I wait.
Thanks,
Mike.
I never put anything on there. Mine has never leaked from there.

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post #10 of 13 Old 01-09-2013, 11:38 AM
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only us liquid pipe dope, teflon could react to the oil...but I used tape on mine, just a tiny bit.

What this nation needs is cleaner thoughts and dirtier fingernails...
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