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Old 03-23-2008, 08:30 AM   #1 (permalink)
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Angry Differential Cover a Year Later

While getting my truck ready for a car show I looked underneath it to see how the blue bowtie was holding up on my differential cover. I was shocked to see what had happened to my cover. I knew I had taken a picture of the cover when I put the bowtie on and found it. The date of that picture was 3/3/2007. Attached are both. So in little over a year my cover has lost almost half of its paint. This truck is not a daily driver. It has 18k miles on it. I can probably count the number of times on one hand that it's been driven in the rain. Never in water where it was up to the differential. I moved from Las Vegas to Williamsburg May 2007. I lived on the east coast my entire life prior to moving to Las Vegas in 2001. I moved to Vegas from eastern NC where I was there for 16 years. I have never seen this on two year old vehicles. I'm either going to POR 15 it or visit Mike's site and get one of his aluminum. Before I do anything I'm going to pull the filler plug and check the fluid level. If it's low she's going to the dealer.

I need to look the frame over. Especially where the Vegas dealer performed some corrosion work just after I bought the truck.
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differential-cover-year-later-no-rust-cover.jpg  differential-cover-year-later-rusty-cover.jpg  
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Old 03-23-2008, 08:37 AM   #2 (permalink)
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Thats quite a difference, you think it could have something to do with the road salts used in Virginia? Maybe I better getunder mine and check for rust as well.

I do drive in rain and other conditions.
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Old 03-23-2008, 08:38 AM   #3 (permalink)
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Hey Bagger,

When I pulled my diff cover off last year to put the aluminum one on, I set the old one outside on a covered shelf. It had a little rust bubbling under the paint at the time, but I didn't think about it. I saw it last week and the rust is really deep into the steel and the paint has almost completely flaked off.

I don't know what kind of steel they used when the made these covers, but I'll bet the differential materials (aluminum housing & steel cover) have something to do with the propensity for corrosion. I would also guess that the vendor did a very poor job of coating the cover.

Happy Easter,

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Old 03-23-2008, 08:38 AM   #4 (permalink)
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...

Must be something in prep work before paint, as my 03 with 17k looks better than your first picture.
Even the paint on the axle looks thinner in your second picture.




I did have mine undercoated at the dealer.
I did buy the electrical ion charge thingy to slow down rust, at the dealer.
And I was going to have the inside panels sprayed with oil guard, but dealer talked me out of it.
rethinking that at this time.
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Old 03-23-2008, 08:41 AM   #5 (permalink)
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Man I can't believe that's the same cover.



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Old 03-23-2008, 08:47 AM   #6 (permalink)
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Bad choice of metal used plus probably poor prep work by vendor and cheap paint. They may have painted over rust that was already forming on the cover. I'm going to check mine when I take it out for spring.

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Old 03-23-2008, 09:21 AM   #7 (permalink)
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Get ready Mike. Looks like you may be selling a lot of covers soon.
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Old 03-23-2008, 09:21 AM   #8 (permalink)
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Quote:
Originally Posted by Focks View Post
Thats quite a difference, you think it could have something to do with the road salts used in Virginia? Maybe I better getunder mine and check for rust as well.

I do drive in rain and other conditions.
No salt used in SE Va. Just sand. And the truck does not go out on the road when those conditions exist.
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Old 03-23-2008, 09:26 AM   #9 (permalink)
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Quote:
Originally Posted by Mike in AZ View Post
When I pulled my diff cover off last year to put the aluminum one on, I set the old one outside on a covered shelf. It had a little rust bubbling under the paint at the time, but I didn't think about it. I saw it last week and the rust is really deep into the steel and the paint has almost completely flaked off.

I don't know what kind of steel they used when the made these covers, but I'll bet the differential materials (aluminum housing & steel cover) have something to do with the propensity for corrosion. I would also guess that the vendor did a very poor job of coating the cover.

Happy Easter,

Mike
Sounds like your cover looked like mine. Wonder if they were in a slight rush getting the 06's out? I blew up the original 3/3/07 picture and I can see the same bubbling talked about. I just went to your site and I think I'm going to order the black cover. Going to PM you a few questions.

I didn't realize the housing was aluminum! Geez....I wonder what it would have looked like if it was steel!
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Old 03-23-2008, 09:39 AM   #10 (permalink)
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Quote:
Originally Posted by Mike in AZ View Post
When I pulled my diff cover off last year to put the aluminum one on, I set the old one outside on a covered shelf. It had a little rust bubbling under the paint at the time, but I didn't think about it. I saw it last week and the rust is really deep into the steel and the paint has almost completely flaked off.

I don't know what kind of steel they used when the made these covers, but I'll bet the differential materials (aluminum housing & steel cover) have something to do with the propensity for corrosion. I would also guess that the vendor did a very poor job of coating the cover.

Happy Easter,

Mike
Mine was the same way. The 6 speed diff is not aluminum, just the autos. Also, the galvanic corrosion would attack the aluminum not the steel cover. Bottom line is poor prep and paint from the factory
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Old 03-23-2008, 09:56 AM   #11 (permalink)
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Quote:
Originally Posted by Bagger View Post
..... I didn't realize the housing was aluminum!
Quote:
Originally Posted by hdflstf View Post
......... The 6 speed diff is not aluminum, just the autos.
Pardon my assumption that the 6 speed housing was aluminum....... I stand corrected. My bad.

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Old 03-23-2008, 12:59 PM   #12 (permalink)
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Talking

When you compare the two photos you can see where the rust was well under way and starting to come through the paint in photo #1. My '05 didn't have anything at all that looked like rust or discoloration. But, I had to have one of the high polished aluminum covers for three reasons. They look way nicer, they hold more fluid, and they have a drain plug.

Maybe your SSR is telling you that it needs a fancy cover.
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Old 03-23-2008, 01:02 PM   #13 (permalink)
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When we installed Mike's pipes on the Bunny, the rear cover looked just like yours Bagger.

That prompted me to buy one of Mike's diff covers to replace it.

I sense a recurring theme here.....
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Old 03-23-2008, 01:10 PM   #14 (permalink)
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Guess I (and all the other So Calif nuts) will take a good look at our differential cover next weekend during the Tech Session.
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Old 03-23-2008, 02:30 PM   #15 (permalink)
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Just checked mine

Almost 3 years later, not too bad looking.

But found some fluid seepage from the transmission.


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Old 03-24-2008, 10:53 AM   #16 (permalink)
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Almost 3 years later, not too bad looking.

But found some fluid seepage from the transmission.


Mine looks this good as well....I just ran out and checked it.
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Old 03-24-2008, 11:05 AM   #17 (permalink)
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Guess I (and all the other So Calif nuts) will take a good look at our differential cover next weekend during the Tech Session.
As I was reading the thread.. that was exactly what I was thinking...
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Old 03-24-2008, 06:13 PM   #18 (permalink)
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As I was reading the thread.. that was exactly what I was thinking...

Is that all you ever think about????? c'mon Linda.... get a grip......... or, is that what you are implying??????


YA-HAHAHAHA
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Old 03-24-2008, 07:13 PM   #19 (permalink)
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Quote:
Originally Posted by RUN ROD RUN View Post
Guess I (and all the other So Calif nuts) will take a good look at our differential cover next weekend during the Tech Session.
Quote:
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As I was reading the thread.. that was exactly what I was thinking...
Don't know that I'd admit thinking exactly like RRR
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Old 03-24-2008, 09:44 PM   #20 (perma