Replacement Differential Covers

The primary function of a basic removable differential cover is to allow set up and repair of the differential, ring and pinion set, and bearings contained within the axle housing. The cover also protects internal components from dirt, debris and moisture. Such covers are typically formed from steel stampings and found on the solid rear drive axles on many cars and trucks and the solid front drive axles on some four-wheel drive trucks. However, when vehicles are equipped with systems like independent suspension and differential oil coolers, differential cover configuration and construction material can vary. However, no matter what type of differential and axle setup is on your vehicle, if you’re in need of a replacement differential cover you’ll find it right here on our digital shelves.

Not so long ago, removable differential covers were unnecessary because most vehicles came with solid drive axles consisting of cast iron differential housings bolted to welded steel axle housings. Such axle housings were called “banjos” because the round center section joined to an axle tube resembled the musical instrument. Differential covers weren’t needed because the differential housing could be removed from the axle and the ring & pinion gearset, differential case and other internal components serviced with the differential housing resting on a workbench. Differential covers became essential when most vehicle manufacturers switched to integral axle assemblies where the steel axle tubes are joined directly to the cast iron differential housing. This type of axle assembly is simpler and less expensive to produce. Covers also facilitate removing and installing the “C-clip” axle shafts found on many solid drive axle assemblies. These axles rotate on roller bearings pressed into the ends of the axle tubes and they’re retained in the differential case by C-shaped clips that fit into grooves on the axle shafts and recesses in the differential side gears.

While stamped steel differential covers are still providing satisfactory service on solid axles, which remain the preferred drive axles on most trucks, they would be inadequate on many of the axle housings found on the increasing number of vehicles with independent suspension. Instead of being attached to suspension members and moving up and down as the suspension reacts to road irregularities, as a solid axle does, with independent suspension the drive axle mounts to the vehicle frame and often consists of little more than the differential housing. In addition to protecting and providing access to the differential internals, on these vehicles the differential covers do double-duty as an attachment point for the differential assembly and incorporate one or more differential mounts. Instead of stamped steel these covers are thick castings made of iron or aluminum. Some performance cars come with or feature optional differential oil coolers, and the differential covers on these vehicles often incorporate the attachment points for the cooler lines.

Differential covers are generally very reliable components, but in addition to deterioration due to heat and age, their mounting location also makes them susceptible to damage from the elements, road debris and road salt. Temperature extremes and age can harden differential cover gaskets, resulting in leaks. Exposure to water and road salt can rust stamped steel covers and extreme corrosion can cause perforation and fluid leaks. Whether it’s due to impact damage from road debris, corrosion or gasket failure, differential leaks should not be ignored. If repairs are not made in a timely manner, the lack of lubrication could cause more expensive damage to the ring & pinion gearset, differential components and bearings. In addition to leaks, cast iron and cast aluminum covers can also suffer stress cracks and in severe cases broken castings.

Regardless of symptoms or the need for repair, we have the replacement differential covers that will restore proper oil retention, vehicle performance and reliability. We offer differential covers and related components that are made to original equipment specifications, so when repairs are completed you can count on the performance and durability your vehicle was designed to deliver. Along with all types of differential covers, we also have differential cover gaskets, seals, and O-rings, cover mounting bolts, and cover drain and fill plugs. Some of our differential covers come as kits that include a gasket and mounting bolts, so you get everything needed for the repair, and many of our stamped steel covers are coated to resist corrosion. We even offer replacement steel covers for the center sections on select banjo axles, to avoid having to replace the entire axle assembly. Cut the rusted and leaking steel section from the banjo, weld our replacement cover section in place, and save money in the process.