Chrysler/Dodge Front Differential Cover
C205FD 8" Ring Gear, 12 Bolt
For Ram 1500, Dakota, Durango

P/N 11046

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Price includes differential cover, vent fitting, bolts, fill hole plug and magnetic drain plug.

Volume: approximately 0.25 quarts over stock

Dimensions: Click here for dimensions. Check for clearance with wheels straight, left and right and at limits of suspension. When the steering linkage moves, clearances change.

For this differential cover design, PML included a bit of extra capacity, some fins, a fill and level check hole, and a drain hole. Aluminum construction and fins will provide cooling and the drain plug will make easier oil changes. The top boss is machined for the vent (included).

Applications for this cover include:

• Dodge Ram 1500 4WD, around 2001 to 2011
• Dodge Dakota 4WD, around 2000 to 2004, and possibly 2005 to 2012, may require modifications
• Dodge Durango 4WD, around 2000 to 2004, and possibly 2005 to 2012, may require modifications
• Some models of Mitsubishi trucks and SUVs

Because there is little clearance, removing the stock cover is difficult. The drain on the PML drain hole simplifies future fluid changes and servicing. A magnetic drain plug is provided. The differential cover also has oil fill/level check hole and boss which can optionally be machined for a temperature sending unit.

Installing the larger PML cover can be challenging. There is very little space. See the INSTALLTIONS section below. Dakota and Durango vehicles have had clearance issues with the steering rack and have made modifications to increase clearance.

Thanks

This project is the result of the many Dakota, Durango, and Ram 1500 owners contacting us and providing information, pictures and notes on their installations. Dodge does not provide any information to us on what vehicles have this front differential and we rely on our customers to let us know the configuration on their truck or SUV. Our thanks to our customers for all your help! More input is always welcome.

Matching Rear Differential Cover

PML makes rear end covers for the Dodge 9¼" and the Dodge 8¼". Please see our part number 9518 for the 9½" and part number 9864 for the 8¼".

Temperature Sending Unit

The option to have PML drill and tap the boss for the temperature sending unit needs to be ordered over the phone, not on-line, and there is a $40 machining charge.

PML Differential Cover Compared to Stock

  
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These images show this PML differential cover compared to the stock cover.

Installations

We have had installations on Ram 1500 trucks, Dakotas and Durangos.

2007 Ram 1500 5.7 PML Front Differential Cover Installation

Roger installed this PML front cover on his 2007 Ram 1500 5.7 4x4. A top bolt is difficult to access so he constructed a tool (picture on right).

Pictures below show the stock cover, Roger's truck and the PML cover installed, and all the tools he used to install it.

   
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2003 Ram 1500 5.9 PML Differential Cover Installation

These pictures show Gary's 2003 Ram 1500 5.9 4x4 front end with a prototype PML differential cover installed.

PML supplies hex bolts with the cover to replace the stock bolts. Gary was unable to get an allen wrench in the head of the top bolt to tighten it with the power steering gearbox being so close. He re-used one of his stock bolts and tightened it with a wrench. Other than that, everything went smoothly.

The capacity with stock cover was 1.75 quarts and with the PML cover his capacity was 1.9 quarts.

The middle image shows the hard to access top bolt next to the vent fitting. The images on the right show the truck, stock cover on top and the PML cover installed on the bottom. Our thanks to Gary for his feedback and pictures.

Gary has also a PML 618 transmission pan and rear differential on his truck.

2004 Dakota 4.7 PML Differential Cover Installation

Joe reported that his installation of PML's Chrysler 8.0 inch IFS cover went well. See his excellent write-up in his 2004 Dakota PML Differential Cover Installation PDF File. Our thanks to Joe for sharing his notes and pictures.

   
   
Some of Joe's pictures from his installation show (left to right):
Joe's Dakota, a difficult to access bolt, the end of the steering rack mounting bolt
Joe's tools and PML cover, RTV he used, PML cover installed
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2003 Durango 5.9L AWD

Frank successfully installed this PML front cover on his Durango. He added a spacer to his steering rack bolt because there was not enough room between the steering rack bolt end and the cover. Frank has put hundreds of happy miles on his Durango since installing the PML cover.

Read Frank's complete write-up with additional pictures of his installation on his website snowdigger.com.

These images show the stock cover. In the first picture you can see the steering racking mounting bolt sticking out of the nut, very close to the stock cover. The next two pictures show the other end of the bolt before the spacer and after the spacer.
   
Views of the PML cover installed (note the steering rack mounting bolt no longer protrudes out the nut):
   
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2005 Ram 1500 PML Differential Cover Installation

Scot installed a prototype PML front differential cover on his 2005 Ram 1500 4x4 front end. He provide images and notes on his installation. Our thanks to Scot for his feedback and help.

The first image shows the space between the steering and the stock cover. The middle image shows vent tube removed from the stock cover. The last image shows the PML cover installed.

Scot's installation notes:
Due to space restrictions, Scot was unable to remove the top right bolt with a socket and ratchet, so it was necessary to use a wrench. This posed no inconvenience in the procedure. Once all surfaces were cleaned, he did a dry fit with the new cover to see what would be the clearest path to mate the surfaces without getting sealant all over. The cover was easily placed without any interference. He put a ¼" bead of Permatex RTV sealant around and between each bolt hole, prepped all the bolts with washers, and put a little Loctite blue on the threads.

2004 Durango 5.7 Hemi AWD PML Differential Cover Installation

Mike at M.P.R. installed an early version of this differential cover on a 2004 Durango with 5.7 Hemi engine, AWD. The cover fit fine as shown on the left. But when the Durango ran for a while, fluid was forced out of the top of the vent. Mike provided some suggestions and we modified our vent design. Our thanks to Mike for all his help.

M.P.R. does custom performance modifications.

2001 Dakota PML Differential Cover Installation

The image below show this PML differential cover installed on a 2001 Dodge Dakota 4WD 4.7. Our thanks to Troy for installing the cover and providing feedback and pictures.

Troy had to remove the steering rack mounting nut and push back the bolt into the frame in order to get the old cover off and the new cover on (first picture). The steering rack mounting bolt and the fins are 1/8" apart but he does not believe that this will be an issue on as there is no way for the steering rack to move as it is bolted to the frame as is the front differential. Vent is attached to the rubber hose as shown in the middle picture.

Image at left shows PML cover and stock cover.

After verifying the fit, Troy ground off the top of one fin to allow more clearance for the steering rack mounting bolt and then powder coated the cover a custom smooth, shiny black.

Similar Applications and Models

Vehicles have a variety of configurations. And some earlier or later year models may or may not have the Dodge 8" front differential.

12 Bolt Dodge Compared to 10 Bolt Dana Cover

Be sure to check that you have the 12 Bolt Dodge 8"/205mm differential. Some vehicles have a similar cover.

Image at left shows a 10 Bolt Dana cover from a 1997 Dakota. Shapes are similar but the Dodge 8"/205mm front end cover has 12 bolts.

2012 Ram 1500 4x4 Stock Cover

Picture shows the stock front cover on a 2012 Ram 1500 4x4 Sport Model.

We had heard that 2012 and newer Ram 1500 trucks have a new design for the front differential. PML does not make cover to replace this stock cover. If your truck has a different front end, please let us know.

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PML Differential Cover Features:

• Increased oil capacity for cooler temperatures
• Sand-cast aluminum with raised fins
• 3/16-inch thick wall construction to add strength to differential housing
• 3/8-inch thick gasket flange will not bend when bolts are tightened
• Machined gasket surface for a secure seal using RTV or factory reusable gasket
• Oil changes without removing the cover
• All hardware provided, including magnetic drain plug

Learn more about finishes and construction of PML parts.