2008-2010 Ford 6.4L Powerstroke Axle & Driveline Parts

Axles and driveline on the 2008-2010 Ford 6.4L Powerstroke

The 6.4L Powerstroke years of the Super Duty used two different front axles and several rear axles, and which ones you have depends on the model and on whether the truck has single or dual rear wheels. Four-wheel-drive F-250 and F-350 pickups use a coil-sprung Dana 60 monobeam with a 9.75-inch ring gear and 35-spline outer shafts. F-450 and F-550 trucks get the Dana Super 60 wide-track front with 3.75-inch axle tubes.

Out back, F-250 and single-rear-wheel F-350 trucks ride on the Sterling 10.5, a full-floating axle with a 10.5-inch ring gear and 35-spline, 1.5-inch shafts. Dually F-350s and the F-450/F-550 step up to heavier Dana rears; Ford's lube chart lists the Dana 80 and the S110, S130 and S135 alongside the Sterling. The F-450 pickup came with a 4.30 or 4.88 ratio, 19.5-inch 10-lug wheels and the wide-track front for a tighter turning circle.

Ratios across the lineup run from 3.31 to 4.88 depending on model and tow package. The two-character axle code printed under the bar code on the door-jamb label is the only reliable way to know yours: 31 is 3.31, 35 is 3.55, 37 is 3.73, 41 is 4.10, 43 is 4.30 and 48 is 4.88 with an open differential, while codes such as 3H, 3J, 3L, 4N, 4W, 4L, 8L and 5L mean limited slip.

What wears out and why

The sources we work from do not document a widespread axle or differential failure on 2008-2010 trucks. The axle work that does show up is ordinary high-mileage wear: pinion seals, bearings and hub unit bearings, plus the damage that follows gear oil left in too long. The symptoms owners commonly report are a howl under load, gear oil weeping from a pinion or axle seal, and hub bearing noise. Those reports are anecdotal, so treat them as things to check rather than a known defect.

Lube neglect is the part you control. Ford's schedule puts axle lube service at 150,000 miles for an F-250 or F-350 in normal use, and at 50,000 miles for F-450 and F-550 trucks or any truck on the severe-duty schedule.

Stock replacement vs. upgrade

For most owners, stock replacement on this system means a cover-off service with a fresh gasket and the right gear oil. Ford calls for SAE 75W-90 to 75W-140 in the rear, depending on which axle you have, and SAE 80W-90 in the front, which holds about 2.9 quarts. Rear capacity ranges from 3.45 to 12.25 quarts across the different axles, so look yours up before you buy oil.

The bolt-on upgrade is an aftermarket differential cover. The PPE covers here are heavy-duty cast aluminum, and ATS sells a drain plug made for its own covers. If you have changed tire size or the way you tow, the bigger move is a re-gear or a limited slip added within Ford's factory ratio set, and that job starts with reading your axle code.

What we carry

This collection covers the differential end of the driveline:

• Front covers for the Dana 60: PPE heavy-duty cast aluminum 10-bolt, Mag-Hytec 60-FF and SPE Motorsport.
• Rear covers: Sterling 10.25/10.5 12-bolt covers from PPE, Mag-Hytec, SPE Motorsport, BD Diesel and ATS Diesel Performance, a Mag-Hytec cover for the Dana 80 rear, and the AFE Street Series cover.
• Cover gaskets: Mahle P32716, P18562, P38163TC and P38155TC.
• Gear oil: Hot Shot's Secret ADRENALINE and Blue Diamond synthetics, Lucas Oil synthetic and heavy-duty grades, and Royal Purple Max-Gear 75W-140.
• Additive and hardware: Motorcraft XL-3 additive friction modifier and the ATS drain plug for ATS pans and covers.

Fitment notes

Match the part to the axle housing, not just the year. Front covers only apply to four-wheel-drive trucks, and the Dana Super 60 wide-track front on F-450 and F-550 trucks is excluded from many F-250/F-350 steering and suspension kits, so do not assume a front part crosses over. At the rear, a cover made for the Sterling 10.25/10.5 is for that axle; a truck with a Dana 80 or S-series rear needs a part made for that housing. Some rear covers here are titled for single-rear-wheel Super Duty trucks.

Small parts also change between generations on the same axle. Dana 60 sway-bar end links use a bushing at the bottom and a stud at the top on 2005-2007 trucks, bushings top and bottom on 2008-2010, and studs top and bottom on 2011-2016. Verify by VIN, the door-jamb axle code and the tag on the axle itself.

Frequently asked questions

How do I tell which rear axle my 6.4L Super Duty has?

Start with the axle code on the door-jamb label, which gives the ratio and whether the axle is open or limited slip. Then read the tag on the axle. F-250 and single-rear-wheel F-350 trucks use the Sterling 10.5, while duallies and F-450/F-550 trucks use heavier Dana rears, so the tag settles which one you have.

What gear oil goes in a 2008-2010 Super Duty?

Ford lists SAE 75W-90 to 75W-140 for the rear, depending on the axle, and SAE 80W-90 for the Dana 60 front. In this collection, 75W-90 comes from Hot Shot's Secret and Lucas Oil, 75W-140 from Lucas Oil and Royal Purple, and 80W-90 from Lucas Oil. Match the grade to your axle, not to whatever the last owner used.

How often should the differential fluid be changed?

Ford's schedule calls for 150,000 miles on an F-250 or F-350 in normal service and 50,000 miles on F-450/F-550 trucks or under severe duty. A seal leak or a howl under load is a reason to look sooner than that.

Should I re-gear after going to bigger tires?

Re-gearing or adding limited slip within Ford's factory ratio set is the documented route when tire size or towing changes. Read your axle code first so you know the starting ratio. Dana 60 front carrier parts are ratio-specific, with a break between the 3.54-4.10 and 4.56-7.17 ranges, so your target ratio decides which carrier parts you need.

Will axle parts from a newer Super Duty fit my 2008-2010 truck?

Some will and some won't. Many covers here are listed across wide year spans, like the PPE Dana 50/60 front cover listed for 1994-2026 Power Stroke trucks. Smaller parts do change, such as the Dana 60 sway-bar end links that went to studs top and bottom for 2011-2016. Check the listing's year range and run the fitment checker.

Not sure what fits? Call the shop at the number in the header, or use the fitment checker on any product page. We install everything we sell.