OEM Rear Differential Cover enhancement project

[TurboS]

In July of 2022, 3 months prior to taking delivery of my Bronco Raptor, I ordered a OEM rear aluminum differential cover from Ford anticipating I would finish the rough casting and have powder coated similar to what I did with my SuperDuty OEM rear diff cover. It didn't arrive before my Raptor, actually 15 months after I took delivery, 18 months waiting in total.

Pic below of my diff cover as delivered except for painting the "R" in Code Orange.

I used my Dremel tool with a metal cutting wheel to remove the casting risers and other small imperfections. Followed by a file to straighten the rough cuts from the Dremel, then sanded by hand with Emery cloth.

My plan was to have it powder coated in "Super Chrome" with a clear coat which actually looks like polished aluminum as on my SuperDuty as seen in the photo below.

At the last moment I decided to have it done in "Polished Aluminum" rather than Super Chrome. The "R" is done in Prismatic Powders Ford Code Orange PSS-11333. The result isn't what I was expecting, I was hoping for a brighter polished look. I considered paying again to have it redone in Super Chrome but the guys did such a good job I decided to install this cover for this year and next winter I'll do the same process to the now removed original cover and have it finished in Super Chrome powder coat.

The bolts are Marine grade A4-70 (316) stainless steel, ordered from Accu-Components.com. The wiring holders are 1/2" Ancor Marine Stainless Steel cushioned clamps that I enlarged the mounting hole using my dremel with small grinding wheel. I wanted the electical wiring to go around on the outside for maximum exposure of the diff cover.
Reusable gasket.
Mounting bolts torque value is 20NM +25 degrees.

In case your curious to what’s under there:

Added May20, 2024.
As mentioned above, it's a reusable gasket.
Mounting bolts torque value is 20NM +25 degrees.
And exactly 2 quarts of this synthetic gear lube shown below.

 

[Dewars]

Well done sir! Looks great!

 

[Stevema7424]

Looks awesome, lot of work it seems, but paid off for sure.

 

[TurboS]

Well done sir! Looks great!

Looks awesome, lot of work it seems, but paid off for sure.

Thank you, now that I’ve seen it outside in the sun I like the “polished aluminum” better than I expected vs the “super chrome” powder coat.

 

[Tye]

wanted to clarify if we are going to remove the diff cover i'm assuming need to catch all the oil and add new oil when reinstalling ?

 

[TurboS]

wanted to clarify if we are going to remove the diff cover i'm assuming need to catch all the oil and add new oil when reinstalling ?

Correct, need an oil drain pan under the differential and I prefer to drain after the vehicle has cooled. Loosen the top 2 bolts backing them out approximately 1/8" to be used to hold cover, then remove the remaining 12 bolts, using a large flat head screw driver or small pry tool, gently pry the bottom of the cover away from the differential housing just enough to allow the gear lube to drain while being careful not to harm the reusable rubber gasket. It's gear lube, so its a thick consistency therefore it won't gushing out like motor oil. Once drained, then push cover tight to the housing and remove the upper 2 remaining mounting bolts, then remove the cover.

 

[ABQBr1]

Correct, need an oil drain pan under the differential and I prefer to drain after the vehicle has cooled. Loosen the top 2 bolts backing them out approximately 1/8" to be used to hold cover, then remove the remaining 12 bolts, using a large flat head screw driver or small pry tool, gently pry the bottom of the cover away from the differential housing just enough to allow the gear lube to drain while being careful not to harm the reusable rubber gasket. It's gear lube, so its a thick consistency therefore it won't gushing out like motor oil. Once drained, then push cover tight to the housing and remove the upper 2 remaining mounting bolts, then remove the cover.

Sorry this is off topic. Where did you get those exhaust tips and did you have to modify them so they would only peek out?

 

[TurboS]

Sorry this is off topic. Where did you get those exhaust tips and did you have to modify them so they would only peek out?

No problem, those are the Borla exhaust tips, Borla has designed all their Bronco & Bronco Raptor systems like this for higher clearance.

What did you do to your Bronco Raptor today?

Thanks for the details. Glad you are almost home! It’s running like normal, but I threw my bike rack and bike on the back when I got home. It’s like having a life boat!

www.broncoraptor.com

 

[ABQBr1]

Ah, yes. That would explain it. I love the look. Nice rig and thank you for the response.

 

[Helipilot]

Thank you, now that I’ve seen it outside in the sun I like the “polished aluminum” better than I expected vs the “super chrome” powder coat.

View attachment 13714
View attachment 13715

This is such a good look. I think I’m going to copy your efforts. Thanks for the idea.

 

[Rguest3]

I have changed the Diff fluids in 2 of my Broncos. They need fluid a lot earlier than you think. I did mine at 5K miles with lots of Charcoal Gray metal present.

Dana recommends (not Ford) 75w-140 Diff fluids in all their Axles. I would assume it's the same for the Raptor Dana 50 as well. I will do this soon for my Raptor.

 

[TurboS]

At ~2500 miles mine was also Charcoal Gray, I didn't think much of it as every time I change gear lube it's always a Charcoal Gray. Also I would expect a little break-in wear with new mating gears. I had looked on-line for a Dana 50 gear lube specification but didn't find anything.

 

[Helipilot]

In July of 2022, 3 months prior to taking delivery of my Bronco Raptor, I ordered a OEM rear aluminum differential cover from Ford anticipating I would finish the rough casting and have powder coated similar to what I did with my SuperDuty OEM rear diff cover. It didn't arrive before my Raptor, actually 15 months after I took delivery, 18 months waiting in total.

Pic below of my diff cover as delivered except for painting the "R" in Code Orange.

View attachment 13055

I used my Dremel tool with a metal cutting wheel to remove the casting risers and other small imperfections. Followed by a file to straighten the rough cuts from the Dremel, then sanded by hand with Emery cloth.
View attachment 13049

My plan was to have it powder coated in "Super Chrome" with a clear coat which actually looks like polished aluminum as on my SuperDuty as seen in the photo below.
View attachment 13047

At the last moment I decided to have it done in "Polished Aluminum" rather than Super Chrome. The "R" is done in Prismatic Powders Ford Code Orange PSS-11333. The result isn't what I was expecting, I was hoping for a brighter polished look. I considered paying again to have it redone in Super Chrome but the guys did such a good job I decided to install this cover for this year and next winter I'll do the same process to the now removed original cover and have it finished in Super Chrome powder coat.

View attachment 13050

The bolts are Marine grade A4-70 (316) stainless steel, ordered from Accu-Components.com. The wiring holders are 1/2" Ancor Marine Stainless Steel cushioned clamps that I enlarged the mounting hole using my dremel with small grinding wheel. I wanted the electical wiring to go around on the outside for maximum exposure of the diff cover.
Reusable gasket.
Mounting bolts torque value is 20NM +25 degrees.

View attachment 13051

View attachment 13053

In case your curious to what’s under there:
View attachment 13054

Added May20, 2024.
As mentioned above, it's a reusable gasket.
Mounting bolts torque value is 20NM +25 degrees.
And exactly 2 quarts of this synthetic gear lube shown below.
View attachment 13067

Finally, just over a year since seeing this post, I’ve gotten around to starting this project. Found a used cover online. Spent today getting rid of the casting markers.

 

[TurboS]

Finally, just over a year since seeing this post, I’ve gotten around to starting this project. Found a used cover online. Spent today getting rid of the casting markers. View attachment 17089

Excellent, you're through the hardest and most time consuming portion. I found the riser removal fun!

 

[Helipilot]

Excellent, you're through the hardest and most time consuming portion. I found the riser removal fun!

I was only going to grind off a few today. Then I realized how much aluminum dust I had all over me, so I said F-It, get-er-done.

 

[Helipilot]

Excellent, you're through the hardest and most time consuming portion. I found the riser removal fun!

Just picked it up from powder coating. On to the next step.

 

[Dgchurch]

Great work fellas!!! Love this thread....!

 

[Helipilot]

Detailing in HPR to match my HPR Raptor.

 

[Hayabusa]

Great looking enhancement! What was the time invested in this project Gents? I have no skill and less patience with work like this. I'd end up grinding off an old man finger or two.

Okay, do either of you have a spare diff laying around and are willing to create one of these art pieces with a Code Orange "R"? I'd be happy to be a paying customer as my retirement account has been doing okay in the current market.

Much respect, guys. Your results look fantastic.

 

[Helipilot]

I took a few hours to grind and polish. Then I dropped it off for the Powder Coating. I’ll install it this week.