I'm close to doing the same thing and contemplating a cover with drain and fill plugs too. Any 9.75 cover should work but so far I've only found fancy/pricey covers like that Raptor one.

 

This is not as fancy but half the price:

 

FWIW - Gale Banks has some (7!) interesting 🤓 videos he posted on differential covers. He is selling a product, but IMO he does provide a lot of good info.

My take away was that it probably is it is probably a good idea to stay with the stock shape. Not sure if that shape would be the same on a TruTrac as a stock differential. BTW Spicer makes a cover that looks to be quite similar to the Ford branded one (maybe?) Changing Differential Gear Oil

 

Here's another from Summit Racing, includes bolts and gasket:

 

I bought this cover, it is made of cast iron, seems well made, it mimics the stock shape, the mating face was not that flat,
about .020 non planer, they do include a nice thick gasket .032 thick, with sealer I am sure it would have worked, I reworked it flatter, I believe the Factory aftermarket is made from cast aluminum, it looks to have the same shape, cost twice as much.

 

I usually don't change diff oil unless there is a water intrusion via a vent hole submerged underwater (water crossing). Unlike engine oil, it continues to get contamination thru combustion. I know many change their diff oil routinely, but I don't. Like the oil in a manual gearbox, transfer case, and diff, it is considered lifetime oil.

 

Lifetime oil lmao yea its lifetime oil if you enjoy way shorter lifetime out of your parts

 

I don't have any personal experience with this cover but I know this company was pretty popular in the offroad jeep community.
Ford F-150 / Raptor Sterling 9.75 Differential Cover

 

What about interference with the rear sway bar?

 

not likely

 

Check this PML cover,
Ford Sterling 9.75, Straight Fins


I have one, good fill and drain ports. With all aftermarket covers that are taller(extend further aft), there may be interference with the rear sway bar. I don't have a rear sway bar, so no problem. I chose this cover because it has a simular shape as the Banks cover(fluid flow dynamics) and was less cost. I purchased an aftermarket cover gasket, but reused the OEM gasket because it is very well made and has not leaked after multiple cover installs. $220.

 

What about interference with the spare? I know it can be very close especially if you have upped tire size at all.

 

For the last 2 months I've wavered back and forth about replacing the cover when I install a PowerTrax differential (this week finally!).
I decided in the end (is that a pun?) to get a cover with drain and fill holes that are easier to access than the factory fill on the front side.

The Spicer cover continues to be out of stock everywhere, so I got the G2 cover above. I painted it Cobalt Blue to go along with the blue bling I've got going under the van, lol.

 

Update on the cover:
Today the PowerTrax Grip Pro finally got installed (quite pleased!).
However, the G2 cover specified for a Ford 9.75" DID NOT FIT.
That's great fun to find out when you're all up under there with sealant all over everything, lol.

First, there was clearance issue with the sway bar and we loosened it expecting to try some spacers under the mounts or something later.
But then, the size seemed slightly off and not all the bolt holes lined up.
It was then compared to the factory cover to confirm it is quite similar but not the same.

The carrier itself went in fine as expected, but for some reason the housing for our vans with floating axles is slightly different?
None of my searches have found a type A and type B variation and Ford part numbers seem to be the same as the F150.

Apparently this is an issue with the Dana 44 differential on certain Jeeps.

 

When crawling under one of the vans recently, I discovered that the differential was still quite warm long after the exhaust had cooled, so I was looking forward to the extra heat dissipation, never mind the easier fill location(s) and drain plug for future convenience.

 

Warning: We got all the way to end of my differential carrier swap and found out that the nice cover I bought DID NOT FIT! The stock cover without drain/fill holes or cooling fins had to go back on instead.
After considerable investigation with no results, I finally found confirmation that there are 3 variations of the 9.75" differential housing.
Thankfully, the inside must be the same, it would have been a real pita to find out the carrier did not fit either,

The G2 cover was cleaned up and returned in the original box, still waiting to find out if they reject it because it was painted.

 

I finally found confirmation that there are 3 variations of the 9.75" differential housing.

Do you have a link for this picture. Thanks

 

I ordered a G2 cover for my 2018 to replace the stock cover while up grading to a TrueTrac. Before even attempting to install it, I measured the clearance from the spare to the stock diff cover. I am running 225/75R16 tires so they are about 29.5 " in diameter. The clearance was only about 3/8". The G2 cover is about 3/4" fatter than the stock so it was a no go.

 

At least you didn't paint it before you found out. 🤣

 

Ha! So true! And my plan was to do just that to protect it from corrosion. I will say though, it seemed like a nice product and the hole pattern was spot on.

 

Any updates on proper fitting alternatives with drain holes?

I've got a lot of clearance so a bigger model would fit just fine.

The next time I do a diff fluid change I want to swap to a serviceable unit.

 

The next time I do a diff fluid change I want to swap to a serviceable unit.

Same here. It appears you just have to verify which version of the 9.75 rear end it is for, which is based on year of manufacture.

 

Has anyone had success with the Dana Spicer 10023529 cover?

 

Bumping this thread. All this hassle because Ford couldn't use a **** drain plug.

Does this look like a fun time to anyone?

It should be an easy 10-20 minute job to replace the fluid. Instead, you need to go through that PITA.

For the price of these vehicles it's inexcusable not to use a properly designed differential with both a fill and drain plug.

 

Bumping this thread. All this hassle because Ford couldn't use a **** drain plug.

Does this look like a fun time to anyone?

It should be an easy 10-20 minute job to replace the fluid. Instead, you need to go through that PITA.

For the price of these vehicles it's inexcusable not to use a properly designed differential with both a fill and drain plug.

Differentials have been built this way for more than a century.
Used successfully in much higher cost vehicles than the Transit.
They almost always outlast the car or truck.

 

Also, I wonder if any of these aftermarket companies might be interested in making a Transit specific diff cover that is the same size, linking them this thread so they can see the pictures, like this one in post 20.

With a drain plug, that won't interfere with the sway bar or oversized spare tire (the most common size is LT245/75/16, or 30.5").

For example, PML Ford Differential Covers

If we were to contact them and ask them to make the part, maybe they will oblige. I will buy this. I know there are buyers for this upgrade as the Transit is the number one selling full size van.

 

 

Nice! Do you know if this cover sits any higher/taller than the stock cover? Because I'll be running a 30.5" LT245/75/16 and there's only a tiny amount of space for the factory cover in the factory spare location.

Also, have you done a drain and fill yet with the new cover? Is the fill hole the top of the two holes on the back cover?

 

@Chillis Got a part number for that?

 

10023539 Dana Spicer, purchased at Rock Auto.

 

This is the one I installed;

 

The OEM cover is 1/8" sheet metal, The Spicer aftermarket cover is cast iron with added bumps, so maybe 1/2 - 1 inch thicker. if your clearance is low I would stick with the OEM cover.
IRC the lower of the 2 holes (on the Spicer cover) seemed correct for refilling although I used the original hole in the side of the diff to refill. the OEM gasket is a multi-layer aluminum and rubber gasket used without gasket sealer, I reused it first time No leaks. second time when I installed a Truetac diff and a Spicer cover, reused the gasket again and now have a very slight weepage. The FSM says to replace the gasket everytime. (forget to read that section) easy to use the OEM gasket, No sealant to remove; wipe surface with Alcohol install gasket and you are good to go. only downside is I think the gasket is like $30.

This video shows it well;

 

Differential Cover Gasket - Ford (HL3Z-4036-A)
2015-2023 Ford - hl3z4036a
MSRP: $49.64
Discount: $18.03 (36.3% off)
Sale Price: $31.61

2015-2024 Ford Differential Cover Gasket HL3Z-4036-A | OEM Parts Online

2015-2024 Ford Differential Cover Gasket HL3Z-4036-A

ford.oempartsonline.com

 

Would you rather have to replace a $50 MSRP gasket each time, hassle with a wiring harness, and remove and replace 12 bolts, creating a huge, time consuming, toxic mess, or just remove and replace 1 plug?

 

Fair enough! But if there is a drain plug, you usually don't need to ever remove the differential cover during the life of the vehicle, unless there is a mechanical failure. I know there is some extra fluid you can clean if you remove the cover, but a drain and fill is good enough (and the standard with many vehicles) especially with a magnetic drain plug. And it's much quicker (so very easy to change the fluid regularly) and doesn't require a $50 gasket to be replaced each time.

 

Only diffs with a bottom mounted plug (Toyota for sure) drain the debris with the fluid.
Our diffs, with a plug on the cover, leave the debris in the bottom and the ring gear circulates it when driving.
A $50 gasket every 150,000 miles (Ford)/75,000 miles (me) = $.000333/$.000666 per mile. Not big on my worry list.