Aluminum Expo Diff Cover Finished! - Ranger-Forums - The Ultimate Ford Ranger Resource


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Old 09-26-2010
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Aluminum Expo Diff Cover Finished!

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Thar she be. All painted up in high heat "Ford Red" paint. Looks like Vermillion to me. Oh well. I ended up using a bunch of cutting wheels with my grinder and a sawzall to get it where I was ok with it. Then I used a grinder wheel and a high grit sanding wheel to shave it down. It's not perfect but the wings are gone at least and it looks like a normal diff cover.

So what do you think?

BTW what size is that drain plug socket? The little one is 3/8 so the big one be like 2 or 3 inch.
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Old 09-26-2010
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So what year do these come off of?
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Old 09-26-2010
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expo's with irs. i do belive 03 and up?
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Old 09-26-2010
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02 and up. close!

it was alot of work get those wings off. i wish i would have been more patient with it. maybe practice? i took a little too much off the one side.
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Old 09-26-2010
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Looks good!
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Old 09-26-2010
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Lookin good!
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Old 09-26-2010
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Icon14 Uh huh..............

Quote:
Originally Posted by Masteratarms93 View Post

Thar she be. All painted up in high heat "Ford Red" paint. Looks like Vermillion to me. Oh well. I ended up using a bunch of cutting wheels with my grinder and a sawzall to get it where I was ok with it. Then I used a grinder wheel and a high grit sanding wheel to shave it down. It's not perfect but the wings are gone at least and it looks like a normal diff cover.
So what do you think?
BTW what size is that drain plug socket? The little one is 3/8 so the big one be like 2 or 3 inch.
=====================================
Looks familiar with the exception of the red paint.........I just had mine bead blasted after I cut the ears off via a wood blade in my sawsall:
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Old 09-27-2010
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I put it on the axle today when I got home from school.
I don't like the bottom of the cover doesn't fully cover the bare steel on the differential.
You can see it on yours in the picture above to. I rubbed some extra RTV on it to cover it up though :/

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For my first fab work and like the second time I've used a Grinder I'm pretty happy with it. I get jealous when I see other people on here though cause they managed to get the wings fins ground down so smooth. I wish mine had turned out that way....
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Old 09-27-2010
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Hey kevin to answer your question about that drain, its 1 inch
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Old 09-27-2010
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Kevin you can see here with mine removed where the old sealant was with the expo diff cover you wont have any issues at all..








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