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Call or Text (352) 722-5295Differentials on the 2015-2016 Ford 6.7L Powerstroke
A 4x4 F-250 or F-350 with the 6.7L Powerstroke has two differentials to look after. Up front is the Dana 60-family monobeam axle, holding 2.7 to 2.9 quarts of 80W-90. Out back, F-250 and F-350 single-rear-wheel trucks run the 10.5-inch Sterling, which holds 3.3 to 3.6 quarts of 75W-140 synthetic; Diesel Hub lists its cover gasket as Dana RD52002. Ford offered these rear axles with an optional limited-slip or electronic-locking differential and ratios from 3.31 to 4.30, so two F-350s on the same lot can have different gearing and a different rear differential.
What wears and why
Seepage at the rear cover and gear noise after running low are the rear axle's warning signs. Whine and leaking hub or axle seals point to the front. Ford's intervals are long, 100,000 miles on the rear and 150,000 on the front in normal use, but both drop to 50,000 miles in severe use. A truck that has worked on the severe side of that line and never had the covers off is due for a fluid service.
Factory spec vs. upgrade
Factory spec means the right gasket and the right grade. MAHLE cover gaskets, Royal Purple 75W-140 Max-Gear for the rear and Lucas Oil 80W-90 for the front put a differential back to stock. If you would rather replace the cover than reseal it, PPE, Mag-Hytec, SPE Motorsport, BD Diesel and AFE all make replacement covers. For traction, the factory choices were a limited-slip or an electronic locker that engages a mechanical dog clutch, and Ford's heavy-towing setup pairs 4.30 gears with one of them. The SPE Motorsport Full Lock Differential Kit is the locking option in this collection, listed for 2011-2019 6.7L trucks.
What we carry
Covers from PPE, Mag-Hytec, SPE Motorsport, BD Diesel and AFE. Cover gaskets from MAHLE. Gear oil from Lucas Oil, Hot Shot's Secret (ADRENALINE and Blue Diamond) and Royal Purple. Motorcraft XL-3 Additive Friction Modifier, the ATS Diesel Performance drain plug for ATS pans and covers, and the SPE Motorsport Full Lock Differential Kit.
Fitment notes
The rear figures above are for the Sterling 10.5. The F-350 dually uses a Dana 80 and the F-450 pickup a Dana S110, and those take their own covers and gaskets; the Mag-Hytec Dana 80 cover here is listed for the F-350. Several Sterling covers are marked SRW only, and 4x2 trucks have no front differential at all. Confirm SRW or DRW, 4x2 or 4x4 and your model, and verify by VIN before ordering.
Frequently asked questions
How much gear oil does a full differential service take?
On a 4x4 F-250 or F-350 SRW, plan on 3.3 to 3.6 quarts of 75W-140 synthetic for the Sterling rear and 2.7 to 2.9 quarts of 80W-90 for the front. Dually and F-450 axles are different housings, so confirm their capacity in your owner's manual.
What gear ratios came in these trucks?
Ford offered ratios from 3.31 to 4.30. The 4.30 limited-slip was required with the High-Capacity Trailer Tow Package, which Ford tied to the F-350 DRW. Call the shop with your VIN and we can help you confirm what is in yours.
What should I have on hand before pulling a differential cover?
A new cover gasket or a replacement cover, enough gear oil of the right grade for the capacity, and a drain plug if your cover uses one. If your owner's manual calls for friction modifier in your rear axle, add Motorcraft XL-3. Check the manual first rather than guessing.
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.