Lehman picked a solid axle rear end (Ford 6.75") that is so outdated that common replacement parts are unavailable or are becoming unavailable. I am purchasing a complete set of seals, gaskets, bearings, wheel cylinders, and driveshaft u-joints (all ware parts) so I have 1 complete set of spare parts. I can do my own repairs, but I need the replacement parts. Buy now or cry later.
I was looking for an aftermarket differential cover for the Ford 6.75" rear end. I wanted to get one that had a drain plug … etc …
I have my method of adding a
drain plug of 1/2-20 thread (
I do this for my transmission pans), but then the subject of drilling to fit a Dodge rubber plug came up. It's not a big deal IMHO, as it's not something done really often like engine oil changes, and removing the cover lets one clean / drain the rear axle housing really well.
When they picked the 6.75" rear,
they were plentiful, they were all over the place. They still are "out there", they are lighter than some alternatives, plenty adequate for the task, and preferable to using some rear end I never heard of maybe created in outer Mongolia I think. Seals, gaskets, bearings, wheel cylinders, brake parts, (
pretty common 9" Ford drum brakes) and driveshaft u-joint will be available for a long time, it's the short axle shafts and ring and pinion or spider gears that will get scarce.
Biggest danger to anything I think is danger of axle seal leak going un-noticed leading to low lube level leading to bad axle bearing and then miles eating up an axle itself. Not real likely as the bearing has it's own inner race though, unless not noticed for a long ways.
No welding risk to the cover or pan, I weld a 1/2-20 nut to a piece of 1/8" steel after drilling a 15/32" hole, then run a 1/2-20 tap through. Use two 1/4-20 bolts to secure it in place in pan with just one 1/2" and two 1/4" holes drilled. I use red locktite on the 1/4" bolts, even peen the threads on occasion, use a regular drain plug (
magnetized maybe) & sealing washer. Have not done it on diff cover, but it'd work just dandy. I made a few last time to have on hand. Put it in a place that doesn't interfere with mechanicals (
ring gear). Looks crude, but works, no leaks with hot ATF or MerconV. I liked the rubber plug idea too, just get
extra plugs.