PML Chrysler Front C205FD 12 Bolt Differential Cover

Description

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.

Number of Bolts: 12

PML made this Chrysler C205FD cover in response to Ram 1500, Durango and Dakota owners who wanted an easier way to service the differential. The ring gear is 205mm and is referred to as an 8 inch or 8.25 inch ring gear.

Benefits

Drain hole and magnetic drain plug for easier oil changes
Fill and level check hole and plug at same level as stock cover
A bit of extra capacity
Some fins for cooling
Aluminum heavy duty construction
Boss machined for the vent and vent barb for tube included
Location that can optionally be machined for a temperature sending unit
All hardware provided

Click on image to view larger.

PML designed this cover for the Chrysler front 8" C205FD IRS differential.

Because there is little clearance, removing the stock cover is difficult. The drain on the PML drain hole simplifies future fluid changes and servicing. Magnetic drain plug is provided.

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

Installation Note: Installing the larger PML cover can be challenging. There is very little space. In many cases, you will need to temporarily remove the steering rack lock nut and washer. This may also be required when servicing the differential with the stock cover. See INSTALLATIONS for pictures.

Durango Owners: Durango vehicles have had clearance issues and made modifications steering rack cylinder bolt to increase clearance.

Thanks! This product 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 so we rely on our customers to let us know the configuration on their truck or SUV.

Applications

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

Always check your vehicle to verify configuration and clearance. Configurations vary.

Similar Applications and Models

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

This Chrysler C205FD 12 Bolt compared to Dana 10 Bolt Cover from a 1997 Dakota:

Pictures shows that shapes are similar but the Chrysler C205FD cover has 12 bolt holes. Click on image to view larger.

2012 and newer Ram 1500 4x4 stock front covers:

Picture shows the stock front cover on a 2012 Ram 1500 4x4 Sport Model. PML does not make a cover to replace this.
Click on image to view larger.

Installations

We have had installations on Ram 1500 trucks, Dakotas and Durangos. Our thanks to those who have emailed us pictures of their installations.

2011 Ram 1500
2009 Ram 1500
2007 Ram 1500 5.7
2007 Ram 1500 4.7
2006 Ram 1500
2005 Ram 1500
2004 Ram 1500
2003 Ram 1500 5.9

2004 Dakota 4.7
2001 Dakota

2004 Durango 5.7 Hemi AWD
2003 Durango 5.9L AWD

2011 Ram 1500

Karl installed PML front and rear differential covers on his 2011 Ram 1500 4.7 4x4. He is quite happy with the result.

2011 Ram 1500 4.7 4x4 PML rear differential cover installed OEM front differential cover differential gear and cleaned flange PML front cover installed, clearance to steering PML front differential cover installed
Rear cover is second picture. Click on image to view larger in a new tab or window.

2009 Dodge Ram 1500

Chris installed this PML front differential cover on his 2009 Dodge Ram 1500. He uses PML covers on his other car as well and is very happy with these products. On this truck he also installed Chrysler/Dodge PML rear differential cover P/N 9518 and Chrysler/Dodge PML transmission pan P/N 11079

2009 Dodge Ram 1500 PML front cover PML rear cover PML Transmission Pan
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2007 Ram 1500 5.7

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:

Click on image to view larger.

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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2007 Ram 1500 4.7

This PML differential cover was purchased in the cast finish. The customer did his own black paint and milled off the top of the fins. He also modified the PML level check hole to be a sight glass.

2007 Ram 1500 stock cover side view stock cover level check customer modification vent PML cover installed
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Customer modifications are NOT recommended or approved by PML.

2006 Ram 1500

After removing the stock cover, Ken put the old bolts back to keep the silicon out of the holes. To tightened the PML bolts at the top of the cover, he took a 6mm wrench and cut it down. A torque wrench will not fit but the bolt can be tightened pretty good. He used GOO GONE to clean all the old silicone off gasket surface. He added 2 1/4 quarts fluid.

stock front differential cover front differential gears tools for bolts and fill plug
PML cover installed, view of drain plug view of top of PML cover and vent space between PML cover and steering nut
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2005 Ram 1500

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.

Stock front differential cover, 2003 Ram 1500

PML front differential cover on a 2003 Ram 1500, image 3

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 Ram 1500

Derek installed this PML differential cover on his 2004 Dodge Ram 1500 with a 5.7 Hemi. Although the truck is lowered, the PML cover still fit.

2004 Ram 1500 vent area with PML cover installed PML cover drain plug fill and level check on PML cover driver side view of PML cover
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2003 Ram 1500 5.9

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

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 so he re-used one of his stock bolts and tightened it with a wrench. This is shown in the second picture. 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.

Click on image to view larger in a new tab or window.

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

2004 Dakota 4.7

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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2001 Dakota

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 secondpicture.

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After verifying the fit, Troy powder coated the cover a custom smooth, shiny black.

2004 Durango 5.7 Hemi AWD

Mike at M.P.R. installed an early version of this differential cover on a 2004 Durango with 5.7 Hemi engine, AWD. M.P.R. does custom performance modifications. Our thanks to Mike for all his help for his feedback with development of this cover.

Click on image to view larger.

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 in this PDF on his PML Diff Cover Installation.

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):

Click on image to view larger.

Specifications

Temperature Sending Unit

Optionally, PML can drill and tap for a temperature sending unit at the 4 o clock position on the side of the cover. This would be a 1/8 NPT hole and would include a plug.

Hardware Included

PML includes new hardware with this cover. This includes a magnetic drain plug with a reusable copper sealing washer. Having a drain allows easy servicing of the differential without removing the cover.