Where can i find a good inexpensive rear differential cover to replace the one on my truck that has rusted thru?

4wheelparts has a chrome one for $56? Don't know that I want the chrome, want something that will last.
Any ideas?

 

Junk yard?

 

stock cover rusted through???

Gotta think the truck went thru some high water early on in it's life....

this might have injested a small amount of water inside the gearcase from the vent tube mounted high above the axle.

water, being heavier that oil, would have settled to the bottom of the housing.... is the rust out at the bottom of the cover?

If that's the case, I think a replacement stock cover will last you the life of the truck.

 

I wonder if Ford is still using that epoxy coating on the covers?

I've replaced dozens of Taurus oil pans because the epoxy coating cracket, water got behind it, and because it couldn't drain out eventually rotted out the pans

 

Diff covers usually rust from the outside, unless as previosly posted, water got in there. Even then, it would have to stay there a long time to rust out the cover. The gear oil sloshing around on the inside keeps them pretty much rust proof, unless the truck goes unused for a tremendous amount of time. Usually, the nastiest looking diff cover looks shiny and brand new on the inside.

I'd get another OEM cover, and coat it (on the outside only) with POR15, or some other rust paint. You'll never have that happen again. It's pretty rare to begin with.

 

It rusted thru the outside. I got the truck last March and immediatly changed engine oil and both axles got new fluid and sealer. The inside was nice and shiny looked like brand new. Cousin of mine, major gearhead, says ford has trouble with that. If thats the case I don't want a stock replacement. Found rust proofed one for 25+shipping.