Hi

I'm trying to find the right gasket for the rear differential cover on a 98-up E-250 (5.4L V8, 3.73 limited slip).

I heard the DANA 44 and DANA 60 look quite similar, but the gasket that I got (Victor Reinz, made by DANA, cork + steel shim, re-usable ala 4R70W pan gasket) is 9 1/8" x 10.25" with the DANA 44/60 shape.

Does the DANA 60 use a larger gasket? And which rear end would the E-250 have?

I don't have an actual E-250 to check.

I know this isn't an E-series forum, but the few E-series forums out there aren't very lively.

Thanks in advance!

 

Why not use a Ultra Grey or High Temp. Red gasket sealer?
I prefer quality sealants vs. gaskets on diff. covers and have had better luck with sealants. Gaskets tend to burst when torqued.

Your diff is probably a model 60 or 61. Doe's it have 10-hole cover (like all Dana axles)?

If diff. has 12-bolt holes, it is a 10.25" Sterling. I don't think Ford ever installed 10.25" in an E-series vans.

 

Its got 10 holes.

I found that Victor Reinz's steel shim core + cork gaskets are VERY durable (and made by Dana).
You can re-use them - as I had to do once on a Dodge transaxle.

Cleanup is very easy - you just peel off the old gasket.

I have a Dana gasket here but I THINK its for a 44.

It measures 9 1/8" across, 10.25" vertical.

My Jegs shows the Dana 60 as being 12"+ all around.

 

The steel re-inforced gasket You speak of was called a "tuff gasket". I have used many of these in Spicer (Dana) transmission overhaul kits (for PTO opening). They will never leak! I was unaware that the "tuff gasket" was being produced for diff. covers.

 

My guess is that if it's an E-250 made in 1998 that it would have the sterling 9.75" axle that is the same as found as in our 5.4L powered F-150's. You said you measured the axle at 10.25" on the outside, and that would leave 1/8" space between the ring gear on each end (top and bottom) and it would also allow for 1/8" of material for the pumpkin.

The Dana 44 is a fairly light duty axle; it's similiar in size to the Ford 8.8" axle and comparable in strength. Although it's fairly rugged, I would think that Ford would have put something a bit more heavy duty in a fullsize V-8 powered van.

The Dana 60 is much larger by comparison, and the differential housing is also larger. Are you sure that the gasket you have is interchangeable? I'd check on it before you try to use it on the wrong axle.

I'd do a search on the Sterling 9.75" axle and see if it looks similiar to what you have on your vehicle.

-Flea

 

I don't have the E-250 yet, I ordered it (2003) w/ a 5.4L SOHC V8 and 3.73 limited slip.

I measured the gasket that I got - I think its wrong becuase the Dana 60 measures something like 12"+ all around based on my Jegs catalog.

The gasket I got matches the Dana 44 measurements.

I think I'll just wait to see what size cover it is, return the gasket and buy the right one.

but yeah, I saw pics of the Dana 60 - its huge compared to the Visteon 8.8