Who makes the best heavy duty diff cover?

Solid axle cover is Iron $64.99..interesting.
http://www.solidaxle.com/ProductCart/pc/viewPrd.asp?idproduct=156&idcategory=7
May order one to try at that price I have a LubeLocker 8.25 gasket coming here next week.

Here's another option for a rear diff cover, probably more geared (no pun intended) for on-road use -

http://www.yourcovers.com/

Sand cast aluminum with cooling fins, fill and drain plugs standard, extra 3/4 quart fluid capacity, for our 8 1/4 axles.

They also make extra capacity ****** pans, again sand cast aluminum with cooling fins and standard drain plug. At least for the 45RFE and 545RFE, their present extra capacity pan won't fit without adding spacers to lower the skidplate - but they're prototyping a "low profile" pan with stock fluid capacity, still made of sand cast aluminum with cooling fins and drain plug, that will clear the factory skidplates on our KJ's without any modifications.

No Aluminium, I think I'm going to get one of these Purple Cranium Half spider
one until/if ARB comes out with their diff cover.
http://purplecranium.com/i-89706-dodge-8-25-rear-half-spider-rock-guard.html
A few of these for my lights would be cool as well!
http://purplecranium.com/i-63145-billet-aluminum-race-piston-toggle-switch.html

Wow to Purple spider Nice Ryan! Good price too!~
The PML 8.25 diff cove is $195. has drain & Fill, but as cast aluminum not the best choice for banging it off road. Cast Iron is better (wont crack if hit like aluminum)
I like the Crane diff cover as well (no drain)
The iron by solid axle is the least expensive and has no drain (not available either)
There was a potential design by ARB 8.25 diff cover, but not available from them as of yet.
PML does make also the 42RLE ****** pan that should fit with OEM skid plates and without spacers. I am about to find out as soon to install it.

The Solid Axle diff cover looks pretty good for $65.00!

How about a BDS for a lot less: http://www.jeepkj.com/forum/showthread.php?t=45560

It's nice and stout, too: http://www.jeepkj.com/forum/attachment.php?attachmentid=2963&d=1278638564

I'm interested in the PML cover mainly for the extra oil capacity and potential cooling ability to keep that rear diff healthy and happy.

Might be because I just had to have the rear diff rebuilt because one of the carrier bearings ate itself after only 60K miles.

Right now the KJ is my primary (only) vehicle and seeing all on-road service, mainly interstate miles.

Yesterday after the 22 mile drive to work, 20 miles of that at 65 to 70 mph, I pulled out an infared thermometer to check the ******, engine oil, and rear diff temps. ****** measured 170 F on the stock pan, 130 F coming out of the aux cooler, engine oil filter measured 185 F (diesel with water cooled engine oil cooler), rear diff measured 150 F on the cover w/ Amsoil 75W140 oil. This at 3 PM on a 100 F day in San Antonio.

Anyone have any idea what temps are considered "healthy" for a rear diff, what temps to start becoming concerned, and what temps to say "holy crap something's screwed up"?

Man I wish I had infrared thermometer..handy!
Are you running 8.25 open Diff? Change lube out every 20 k miles or trac-lok way sooner.
Not sure if Amsoil is synthetic, but if it is consider using dino GL5 only 75-140 is good.
Actually I would like you to test with your thermometer this:
http://www.lucasoil.ca/products/product.asp?id=57&cat=Automotive
I think the Lucas would be cooler immediately as it should remove a good amount of friction and stick to gear/metal surfaces better.
PML diff cover is aluminum and not really strong/off road suitable.
I have concerns about extra lube capacities replacement covers as need to be the same design as far as the Lube level and not higher level if you know what I mean.

The Ram guys like PML, I plan on getting a ****** pan from them, I haven't heard anything bad yet:

http://www.pmlcovers.net/category_s/3.htm

retmil46 said:

Anyone have any idea what temps are considered "healthy" for a rear diff, what temps to start becoming concerned, and what temps to say "holy crap something's screwed up"?

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The normal operating temps can reach 200 degrees in the diffs with zero issues.During gear break-in those temps can get even hotter.Reading the temp of the housing is not a good way to measure the rear diff if you run synthetic,you need to measure the ring gear itself as syn gear oil does not tranfer heat to the housing very well like dino gear oil,and read I stated gear oil not engine oil or trans fluid.

Just a comparision my RockJock60 rear never got above 140 degrees,even during break-in running dino 85-140 gear oil.It ran about 130 degrees when I did a 1300 mile road trip back home.

04Liberty said:

The Ram guys like PML, I plan on getting a ****** pan from them, I haven't heard anything bad yet:

You must be registered for see images

http://www.pmlcovers.net/category_s/3.htm

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I have my PML 42RLE here and just waiting for The Lubelocker gaskets to install above OEM ****** skid.
I will be the PML / LubeLocker (KJ) Guinea pig for both real soon.
Should have it installed by Month's end hopefully.
Painted with Temclad flat black 1200F paint.
40650[/ATTACH]"]

Looks good. Waiting on some usage reports once you get that ****** pan installed. Looks like a good option.

LibertyTC said:

I have my PML 42RLE here and just waiting for The Lubelocker gaskets to install above OEM ****** skid.
I will be the PML / LubeLocker (KJ) Guinea pig for both real soon.
Should have it installed by Month's end hopefully.
Painted with Temclad flat black 1200F paint.
40679[/ATTACH]"]

You must be registered for see images attach

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Nice, are you gonna tap that pan for a drain plug (or is that it sticking out the side)?

Drain plug is a standard feature on PML's ****** pans. They also include an extra boss, that you can have them drill and tap or DIY, to install a ****** temp sensor.

I know of several CRD owners that have installed the deep version of their ****** pan for the 545RFE, had to add some serious spacers to lower the factory skid plate to get enough clearance. Friend in Charlotte NC added one of these to his CRD recently - he said that aluminum pan radiates noticeably more heat than the factory pan, and that along with the extra fluid capacity has dropped his fluid temps noticeably.

After the bank account recovers somewhat from all the recent repairs to my CRD, I'm thinking of getting one of the low profile pans they're prototyping for the 545, such that you don't have to modify the skid plates.

It comes with magnetic drain plug, it's on the top there. This is what it looks like inside.
40681[/ATTACH]"]
You also can have $40 machined threads for a temp sensor from PML (optional)
I chose not to as I felt that for machining $40,sensor $50 & Gauge $50 that would do nothing extra to cool, the money would be better spent on an additional ****** cooler with w/electric thermo fan.
This aluminum pan may help in cooling a bit better with an extra quart or so over stock wont hurt either.
42RLE PML Link: http://www.yourcovers.com/transpan_11044.php

One of these on my list for the Ram.

Today the LubeLocker gaskets arrived, quite impressive fit/quality.
40695[/ATTACH]"]
I am ready to get the stronger rear diff cover soon as I got a LubeLocker ready for 8.25.
I wonder with the KJ gas tank skid if the crane would fit, even if it does not have drain.

Good!
Now you can finally go out and get it dirty with us!

Any pics of the PML installed? Am thinking about the black powdercoat one next transmission fluid change.

Did you get a diff cover on? Most seem to clear the gas tank skid - mine has a couple inches safely (RS).

LibertyTC said:

I wonder with the KJ gas tank skid if the crane would fit, even if it does not have drain.

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I have a Crane diff cover and a Kilby gas tank skid which is way heavier/thicker/bigger than a stock skid and it fits fine
Oh and just drained the rear diff the other day same stock gasket glued to the cover and never leaks, have removed it and drained the diffs four times now since I swapped in the 4.10s and its working great. no need for the fancy lube lockers etc