2015-2016 Ford 6.7L Powerstroke Axle & Driveline Parts

Axle and driveline on the 2015-2016 Ford 6.7L Powerstroke

For 2015 Ford refreshed the 6.7L Powerstroke with a new turbo and a 440 hp / 860 lb-ft rating, but the truck around it stayed the third-generation Super Duty, so the axle layout carries over. On 4x4 trucks the front is a solid twin-coil monobeam axle from the Dana 60 family, riding on coil springs. The XL came with manual-shift 4x4 and manual hubs, and electronic shift-on-the-fly (ESOF) with auto/manual locking hubs was optional. 4x2 trucks use Twin-I-Beam up front instead of a driven axle.

Out back, the F-250 and the single-rear-wheel F-350 use the 10.5-inch Sterling, the dual-rear-wheel F-350 uses a Dana 80, and the F-450 pickup uses a Dana S110. Ford rates the rear axle at the ground at 6,200 lb on the F-250, 7,280 lb on the F-350 SRW and 9,650 lb on the F-350 DRW and F-450, with front ratings from 5,250 lb on a 4x2 up to 6,000 lb on a 4x4. The F-450 is the truck that changed underneath for 2015: a new rear axle, new rear leaf springs, new rear driveline U-joints and stronger steering gear and linkages. Every 6.7L pickup in these years puts its power through the 6R140 TorqShift six-speed automatic.

What fails and why

What you will actually deal with on these axles is fluid and seals. Ford's interval for the Sterling 10.5 rear is 100,000 miles in normal service and 50,000 miles in severe service, using 75W-140 synthetic gear oil. Seepage at the cover is the first sign the seal is done, and gear noise is what you hear if the axle has been run low. The 4x4 front differential is on a longer clock, 150,000 miles normal or 50,000 severe, with 80W-90. On the front, owners notice a whine or oil weeping from the hub and axle seals.

Ford publishes a normal number and a severe number for a reason. Pick the one that matches how your truck really works, not the one you wish it matched. Any time a cover comes off, plan on a new gasket and the correct grade of fluid so you are not chasing the same leak twice.

Stock replacement vs. upgrade

A stock-style service is a new cover gasket and the grade Ford calls for. That job is covered here with MAHLE cover gaskets plus gear oil in 75W-140 for the rear and 80W-90 for the front.

The upgrade path starts with the cover itself. Aftermarket covers from PPE, Mag-Hytec, SPE Motorsport, BD Diesel and AFE are listed for the Sterling, the Dana 80 or the Dana 60 front depending on the part, and the PPE covers are heavy-duty cast aluminum. Pick by axle first, then compare features on each product page. On the differential itself, Ford offered a limited-slip or an electronic-locking rear that uses a true mechanical dog clutch to lock the axle shafts together, with ratios from 3.31 to 4.30. The High-Capacity Trailer Tow Package required the 4.30 limited-slip, and Ford's own heavy-towing setup is a locking or limited-slip rear with 4.30 gears. If you want full locking that your truck did not leave the factory with, the SPE Motorsport Full Lock Differential Kit is listed for 2011-2019 6.7L trucks.

What we carry

• Rear differential covers: PPE Sterling 10.25/10.5 12-bolt heavy-duty cast aluminum, Mag-Hytec F12-10.25 & 10.5 and Mag-Hytec 80 Dana 80, SPE Motorsport 10.25 and 10.5 Sterling for SRW trucks, BD Diesel 1061830 for Super Duty SRW, and the AFE 46-70022 Street Series cover.
• Front differential covers: PPE Dana 50/60 10-bolt heavy-duty cast aluminum, Mag-Hytec 60-FF Dana 60 Ford and SPE Motorsport Dana 60.
• Gaskets and hardware: MAHLE cover gaskets P32716, P18562, P38163TC and P38155TC, plus the ATS Diesel Performance 402-009-1000 drain plug for ATS pans and covers.
• Gear oil and additive: Lucas Oil synthetic 75W-140 and 75W-90 and heavy duty 85W-140 and 80W-90, Hot Shot's Secret ADRENALINE and Blue Diamond gear oils in 75W-90, 80W-110 and 85W-140, Royal Purple 01301 75W-140 Max-Gear, and Motorcraft XL-3 Additive Friction Modifier.
• Differential: the SPE Motorsport Full Lock Differential Kit.

Fitment notes

Verify the truck before the part. These Super Dutys came with three rear axles and three wheel bolt circles: 8 x 170 mm on single-rear-wheel trucks, 8 x 200 mm on the F-350 DRW and 10 x 225 mm on the F-450, which also moved to 19.5-inch wheels for 2015. Counting lugs and rear wheels gets you most of the way. Several rear covers here are listed for SRW trucks only, the Mag-Hytec Dana 80 cover is listed for the F-350, and front covers apply to 4x4 trucks only. If yours is a chassis cab rather than a pickup, or you are not sure what is under it, verify by VIN before you order.

Frequently asked questions

Which rear axle is under my 2015-2016 Super Duty?

F-250 and single-rear-wheel F-350 pickups use the 10.5-inch Sterling. The F-350 dually uses a Dana 80, and the F-450 pickup uses a Dana S110. If you are unsure, the wheel bolt circle is a quick tell: 8 x 170 mm on SRW trucks, 8 x 200 mm on the F-350 DRW and 10-lug 225 mm on the F-450.

How often should I change the differential fluid?

Ford lists 100,000 miles for the rear in normal service and 50,000 miles in severe service. The 4x4 front differential is 150,000 miles normal and 50,000 severe. The Sterling rear takes 75W-140 synthetic and the front takes 80W-90.

What is the difference between the limited-slip and the electronic-locking rear?

The electronic-locking differential uses a true mechanical dog clutch to lock both axle shafts together. The limited-slip was the other factory choice. If your truck has the High-Capacity Trailer Tow Package, it came with the 4.30 limited-slip rear axle.

Do differential covers go by model year or by axle?

By axle. That is why the covers here are listed across wide year ranges, like 1994-2025: they are built for the Sterling, Dana 60 or Dana 80 housing rather than a model year. The one to watch is the F-450 pickup, which got a new rear axle for 2015, so do not assume an older F-450 part carries over.

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.