AWD Explorer diff cover

[DFG_magic]

It's been done before, but I decided to do it myself. Took a rear end cover from a 2004 AWD Explorer and modified it. The benefits of the Explorer cover are the nice aluminum finish, cooling fins, and fill/drain ports on the front! With a little time and effort, it came out nice! Saved me from buying an aftermarket cover for my gear install! The Explorer cover has everything an aftermarket cover has minus the adjustment capability!

Here is the stock Explorer cover:

Side by side stock explorer and modified cover:

A few shots of the modified cover:

Check out the laser cut valley around the inside of the cover to ensure a positive RTV seal!

A zizwheel was used to cut the ears off of the stock cover then I ground out the rough edges of the cut to make it smooth. With a little more time and effort, you can really make the cover look great! This is a nice option for those who don't want to spend an arm and a leg for an aftermarket cover! If these covers are modified, they will fit any Mustang with an 8.8 rear!

 

[Blakonblak94]

Awesome idea.

 

[ReplicaR]

I think I might have seen someone do something similar because they had panhard bar clearance issues with T/A Performance diff cover. Came out pretty well

 

[DFG_magic]

Yeah I can't wait to bolt it up. I'll be doing 3.90's in a few weeks.

 

[Blakonblak94]

Do you think itll keep rear end sepage(hehe) down to a minimum, or at least better than stop?

 

[GDTrumbo]

I would still do the OEM gasket. Not hip to the RTV sealer for a DD.

GT

 

[DFG_magic]

I would still do the OEM gasket. Not hip to the RTV sealer for a DD.

GT

I agree. That's standard procedure though. I've always used a light bead on the chunk to position the gasket, another light bead on the gasket, then install the cover. Felpro FTW.

 

[switch96]

You can get diff cover silicone. I'm not a fan of the paper gaskets.