02+ Explorer IRS Aluminum Diff Cover Owners!! HELP - Ranger-Forums - The Ultimate Ford Ranger Resource


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Old 09-19-2010
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02+ Explorer IRS Aluminum Diff Cover Owners!! HELP

I just picked up my IRS Explorer diff cover today, I cut off the the stupid tabs with my angle grinder and that is all done. Looks gewd man.

The guy I bought it from didn't have the bolts for it though and my regular 8.8 bolts don't fit. Does the dealership sell misc. bolts like that?

And for some reason the cover is missing the filler plug thing on the top. It isn't a bolt since there is no threading so I think it may have been a rubber plug?

Any advice?
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Old 09-19-2010
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those covers are weak as f*ck
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Old 09-19-2010
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i don't go off roading. it looks cool and it as drain plugs and cooling fins. I have been looking at how other people are doing them and that are BA. I just rough cut my tabs though cause I am terrible at fabbing. I need to take it somewhere and have them do it.

Its not like I can use it until I get bolts anyway.

https://www.ranger-forums.com/f37/pi...21/index2.html

heres a thread where a few people are running them. they got them new though so they be shiny. i saw on explorer forums that people were paying 25-30 from the dealer new! i paid $50 used and some parts websites like tasca had them for 150-200. WTF

Last edited by Masteratarms93; 09-19-2010 at 04:48 PM.
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Old 09-19-2010
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IIRC, the bolts are common 5/16-18 thread, available at any hardware store. Just pick the length you need. It might be 1 1/4" for the IRS Ex cover but check to be sure.

The small hole at the top of the Ex cover is for a vent that your truck doesn't need. I tapped it with a 1/8 NPT pipe tap and installed a 1/8 NPT pipe plug using pipe sealant. The plug should also be available at any hardware store.

The fill hole on the back of the Ex cover is much too low for an axle like yours where the wheel bearings must also be lubricated with the diff oil. Be sure to fill and set the level of the lube using the side plug in the diff housing.
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Old 09-19-2010
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Quote:
Originally Posted by rwenzing View Post
IIRC, the bolts are common 5/16-18 thread, available at any hardware store. Just pick the length you need. It might be 1 1/4" for the IRS Ex cover but check to be sure.

The small hole at the top of the Ex cover is for a vent that your truck doesn't need. I tapped it with a 1/8 NPT pipe tap and installed a 1/8 NPT pipe plug using pipe sealant. The plug should also be available at any hardware store.

The fill hole on the back of the Ex cover is much too low for an axle like yours where the wheel bearings must also be lubricated with the diff oil. Be sure to fill and set the level of the lube using the side plug in the diff housing.
Like Bob said, go pick up the bolts at any hardware store I bought allen head stainless steel bolts and stainless steel washers for mine too. Also just as Bob did I threaded mine and put a plug in with sealant and removed that plastic plug. (no pic of the plug tho)


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Old 09-19-2010
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GREAT! i was hoping you guys would chime in. i knew bob had a Expo IRS cover.

Since I don't have a bolt to use as reference I have NO IDEA how long that need to be. If anyone knows the length that would be great.

Zach, what did you paint yours with? Power coated? It looks like floor apoxy.
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Old 09-19-2010
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I think thats the rustoleum hammered spray paint
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Old 09-19-2010
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I think thats the rustoleum hammered spray paint
Its powder coated. https://www.ranger-forums.com/f37/in...er-pic-103709/

Looks a lot like the solid one. For the price of the soid one i would skip the expo one all together Poly Performance JEEP/TRUCK & BUGGY :: Drivetrain & Differential :: Differential Housing & Accessories :: Solid Axle Industries :: Ford 8.8 Differential Cover - 4X4 Off-Road, JK Synergy Suspension Systems, Fox Racing Shox, Beard, CNC Brakes, Johnny J
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Old 09-19-2010
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those look pretty sweet
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Old 09-19-2010
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Originally Posted by Masteratarms93 View Post
Since I don't have a bolt to use as reference I have NO IDEA how long that need to be. If anyone knows the length that would be great.
From an old post of mine:
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Originally Posted by rwenzing View Post
I used 5/16-18 x 1 1/4 plus one flat washer for my IRS Explorer cover.
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Old 09-19-2010
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hey so if the irs fill port is too low, who are you filling the diff?
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Old 09-19-2010
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hey so if the irs fill port is too low, who are you filling the diff?
the ranger pumpkin fill..... on the front of the axle... same place it's always been...

lol
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Old 09-19-2010
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shane ftw!


btw dig the new sig!!
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Old 09-20-2010
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hey so if the irs fill port is too low, who are you filling the diff?
.
Quote:
Originally Posted by rwenzing View Post
The fill hole on the back of the Ex cover is much too low for an axle like yours where the wheel bearings must also be lubricated with the diff oil. Be sure to fill and set the level of the lube using the side plug in the diff housing.
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Old 09-20-2010
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Thanks for all the info guys!! I am going to finish taking the wings off on Saturday. I will get hardware sometime this week.

Lol at people not knowing where to fill diff. Come on guys, know where to put your fluids
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Old 09-20-2010
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ya its powder coat hammer finish. it was only $25 to powder coat it so why not at that price
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