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Best Differential Covers (Front & Rear)

ExpeditionBuilds

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yep, I am a function vs. looks guy myself. This is exactly what I was hoping to hear. Thanks!

I do use these. I'm a big fan of Dana parts on Dana housings, but I don't buy diff covers for looks. I buy them for their ability to take a hit, but also to make the housing more rigid. Under load, the housing will deflect causing the gears to not mesh completely. This deflection, for people that wheel hard, is something to keep in mind as the stock cover isn't designed to do anything except seal the housing cavity. Most aftermarket covers are made thick for this reason more than the ability to take the hits. Anyway, I do like the look of the Dana cover, but looks wasn't part of my decision making process. @mgroeger and @OMTBiker are running these covers, as well. @conFUcius and @UNC Rubicon run the Motobilt covers. You can't really go wrong with either.
 

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I do use these. I'm a big fan of Dana parts on Dana housings, but I don't buy diff covers for looks. I buy them for their ability to take a hit, but also to make the housing more rigid. Under load, the housing will deflect causing the gears to not mesh completely. This deflection, for people that wheel hard, is something to keep in mind as the stock cover isn't designed to do anything except seal the housing cavity. Most aftermarket covers are made thick for this reason more than the ability to take the hits. Anyway, I do like the look of the Dana cover, but looks wasn't part of my decision making process. @mgroeger and @OMTBiker are running these covers, as well. @conFUcius and @UNC Rubicon run the Motobilt covers. You can't really go wrong with either.
I like the covers a lot but you should know something about running diff skids with them. On the rear I am running the Metal Cloak golden diaper and the fins of the diff cover do make contact with the diaper. This has not caused ANY problems. You can see the skid rubbed into the cover a little bit until they were both happy living together. So don't freak out if you see this, it has no bearing as the Jeep has had the snot wheeled out of it with this setup for many thousands of miles.
I am running the Rancho skid up front and if you choose to run that skid with this cover you will need to run to the hardware store and buy a long piece of threaded steel. Basically a 12" or so screw with no head on it, the reason is the one Rancho gives you barely fits the diff with a stock cover and when you have the Dana cover on it winds up being just a tick to short. Simply bend the piece of threaded steel you bought into the correct U shape and use it instead. It's very straight forward and the Rancho skid and Dana cover play nice together.
 

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I actually have the Rancho front glide plate and the metalcloak rear diff skid currently which I was planning on getting rid of and replacing with these covers. Do you think running the skids additionally is necessary?

I like the covers a lot but you should know something about running diff skids with them. On the rear I am running the Metal Cloak golden diaper and the fins of the diff cover do make contact with the diaper. This has not caused ANY problems. You can see the skid rubbed into the cover a little bit until they were both happy living together. So don't freak out if you see this, it has no bearing as the Jeep has had the snot wheeled out of it with this setup for many thousands of miles.
I am running the Rancho skid up front and if you choose to run that skid with this cover you will need to run to the hardware store and buy a long piece of threaded steel. Basically a 12" or so screw with no head on it, the reason is the one Rancho gives you barely fits the diff with a stock cover and when you have the Dana cover on it winds up being just a tick to short. Simply bend the piece of threaded steel you bought into the correct U shape and use it instead. It's very straight forward and the Rancho skid and Dana cover play nice together.
 

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I actually have the Rancho front glide plate and the metalcloak rear diff skid currently which I was planning on getting rid of and replacing with these covers. Do you think running the skids additionally is necessary?
YES.
I would not get rid of your diff skids.

Front - The drain plug is exposed on the bottom of the axle and prone to damage which can make for a very bad day. Feel free to read up on my experience with this happening to us on the rear axle before we upgraded to the D44 axles. The Rancho skid protects that plug as well as the front lower portion of the diff cover.
Rear - The diaper does a great job of protecting the FRONT side of the diff and allows you to slide over things.

These covers are meaty and can take a hit but the reality is you don't want stuff hitting them if you can avoid that. The covers you and I have to a great job of OVERALL diff protection... i.e. not just protecting the cover. NOTE: the cover does nothing to protect the rest of the diff.

Both of our Jeeps run the Rancho up front and MC in the rear and both skids have taken a beating and been worth every penny because they kept that beating off of the diff and the diff cover.
 

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YES.
I would not get rid of your diff skids.

Front - The drain plug is exposed on the bottom of the axle and prone to damage which can make for a very bad day. Feel free to read up on my experience with this happening to us on the rear axle before we upgraded to the D44 axles. The Rancho skid protects that plug as well as the front lower portion of the diff cover.
Rear - The diaper does a great job of protecting the FRONT side of the diff and allows you to slide over things.

These covers are meaty and can take a hit but the reality is you don't want stuff hitting them if you can avoid that. The covers you and I have to a great job of OVERALL diff protection... i.e. not just protecting the cover. NOTE: the cover does nothing to protect the rest of the diff.

Both of our Jeeps run the Rancho up front and MC in the rear and both skids have taken a beating and been worth every penny because they kept that beating off of the diff and the diff cover.
I’m actually planning on throwing mine on today once I get over my fear of screwing it up, haha. Doing the Rancho up-front and MC in the rear.
 

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The rear plugs, like is common on Toyotas, can be welded. With my Ox setup and the required cover that’s part of the mechanism, I don’t have another option.

For the front, I’m going with a welded cover rather than the RC or Rancho skid considering the mild to moderate trails we take at the speeds we take them. It’s only a M186 anyway so a later excuse to upgrade.
 

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I’m actually planning on throwing mine on today once I get over my fear of screwing it up, haha. Doing the Rancho up-front and MC in the rear.
If you screw up installing those don't ever talk to me again.
 

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So what are you guys running right now? I’m between the Motobilt ones and ARB.
 

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So what are you guys running right now? I’m between the Motobilt ones and ARB.
I’m running Motobilt on the front and back. No clearance issues with Steer Smarts track bars and will be (still haven’t installed them, haha) compatible with Rancho front diff skid plate and MC rear diff skid.
 

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I’m running Motobilt on the front and back. No clearance issues with Steer Smarts track bars and will be (still haven’t installed them, haha) compatible with Rancho front diff skid plate and MC rear diff skid.
How’d you go about painting them? Powder coat?
 

conFUcius

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How’d you go about painting them? Powder coat?
No - kept the machined look and they were clear coated. Shawn (@chevymitchell) can provide more details as he actually did it when doing my re-gear.
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