Just installed the new Banks ram air differential cover “Black Ops editions”. Not sure if all the hype is true but I do like the way it looks.
Bullseye21
Looks good. Good for street trucks..
Although I don't "off road" my D max, I on occasion may be on a few class 5 roads / goat trails... I don't care for anything that hangs off the diff housing that could get caught and cause major damage...
Although I don't "off road" my D max, I on occasion may be on a few class 5 roads / goat trails... I don't care for anything that hangs off the diff housing that could get caught and cause major damage...
Yeah I can understand that. My truck here in Florida won't see anything off road. Banks says the ears are designed to break off if they get caught on anything but I hope never to see that happen.
From Banks:
Purpose Built
The Banks Engineering team’s goal was to perfect fluid flow and reject BTUs from the fluid as fast the ring and pinion puts them in. If the fluid flow is impeded in any way, it results in resistance and aeration which reduce fuel economy and creates heat, thereby degrading the fluid and decreasing the lifespan of the gearset.
In all studies, the stock stamped steel AAM (American Axle Manufacturing) was used as a baseline. Competitive covers tested included Mag-Hytec, AFE, ATS, BD, PPE and others, with Mag-Hytec and AFE representing the ‘flat-back" design category.
Heat Absorption and Radiation Surface Area Comparison
The Banks Ram-Air cover features 169% more exterior heat radiation surface area and 21% more internal heat absorption surface area than Mag-Hytec. This is impressive considering the Banks cover retains the stock 4-quart fluid capacity.
Road Test: Heat Rejection — Grapevine Trailer Test
Road tests were performed on a stretch of California’s infamous Grapevine (Interstate 5) on the same truck, with the same driver and the same load, at the same time of day and at same temperature. Starting with a nominal 78° ambient temperature, the operator pulled an 11,650 lb weight trailer with a 2018 Chevy Silverado 2500HD 6.6L diesel. Gross combined weight was 19,750 lbs. The rear differential was heated by maintaining a constant speed of speed of 55 mph up a 6% grade for 5 miles, ascending over 1,600’.
At the top of the 550 second hill climb, running the 3.9 quart stock differential cover, the lubricant temp was 205°. Filled with 7.5 quarts, the Mag-Hytec recorded 199° while the Banks filled with 4 quarts recorded 192.5°. Even with less lubricant, the Ram-Air cover controlled heat 2X better than the flat-back during the high horsepower hill climb!
From the crest to the end of the test, running 55 mph for 700 second at relatively constant elevation, the stock cover cooled from 205° to 195°. The Mag-Hytec cooled to 192.5° and 178.5° for Banks, a 4X improvement over the Mag-Hytec and by extension all other flat-back copies.
Chassis Dyno Testing: Heat Rejection — Sustained Power Test
This test was used to determine high load, steady state thermal management. Gale had originally requested a 90 minute, 250 hp test. Gale soon regretted that request. At 90 minutes the lubrication measured 316° and was still climbing. The intense test even resulted in the dyno catching on fire. After repairs were made, the test was revised to 60 minutes at 200 hp.
Testing was started after a 100° nominal temperature was achieved. Using a 2007 Dodge Ram 6.7L 3500 dually, the truck was brought 60 mph and loaded to 200 hp, typical of pulling a heavily loaded trailer up a 6% grade. Lubrication was changed between every test.
The equivalent of 60 MPH road speed air was directed under the truck’s belly using the Banks Wind Machine, aided by additional shop fans. Air damns were constructed to contain the airflow under the truck toward the rear differential.
At the end of the 60 minutes test, the lubrication temp was 289°, AFE was 261° or 28° cooler than stock. Banks was 228° or 61° less than stock. Banks outcooled AFE by 118% and by extension, all flatback covers.
Anemometer: Air Velocity
After affixing anemometers fore and aft of the rear differential, a dead zone was discovered. Like the wing of plane, the rear differential splits the air. At a road speed of 70 mph, air speed was measured at 32 MPH in front of the differential and 11 MPH 20" behind the differential. This indicated an area of dead air.
This low velocity dead zone extends as far out as 36" from the back face of the cover. No matter how deep the cooling fins are, they’re unable to adequately reject heat due to inadequate airflow over the surface of the fins.
This discovery resulted in the Ram-Air scoop concept. As the truck moves through the air, cool static air is forced into the Ram-Air scoops and directed 90° up and through the long, thin heat radiation fins.
Fuel Economy Testing Simulated City Driving
Fuel Economy was tested on the Mustang dyno using the OBD-II fuel flow rate and vehicle speed data, as well as the Banks emissions analyzer to measure fuel economy calculated from tailpipe emissions. The dyno was calibrated to simulate a 7,500 lb vehicle with an engine output of 30 HP required to maintain a 50 mph steady state speed. The truck was warmed to operating temperature then held at a constant 50 mph for a fixed length of time to procure an accurate average fuel consumption. The test was repeated for all covers as per their respective manufacturer’s fill level specifications.
At $3.50 per gallon of diesel, Banks owners will save $251 in fuel for every 100,000 miles driven as compared to stock. Flatback owners will spend approximately $447 in lost fuel economy over stock, enough money to buy another diff cover. Those upgrading from a flat-back design to a Banks cover can will see a $697 savings in fuel economy over their next 100,000 miles.
Purpose Built
The Banks Engineering team’s goal was to perfect fluid flow and reject BTUs from the fluid as fast the ring and pinion puts them in. If the fluid flow is impeded in any way, it results in resistance and aeration which reduce fuel economy and creates heat, thereby degrading the fluid and decreasing the lifespan of the gearset.
In all studies, the stock stamped steel AAM (American Axle Manufacturing) was used as a baseline. Competitive covers tested included Mag-Hytec, AFE, ATS, BD, PPE and others, with Mag-Hytec and AFE representing the ‘flat-back" design category.
Heat Absorption and Radiation Surface Area Comparison
The Banks Ram-Air cover features 169% more exterior heat radiation surface area and 21% more internal heat absorption surface area than Mag-Hytec. This is impressive considering the Banks cover retains the stock 4-quart fluid capacity.
Road Test: Heat Rejection — Grapevine Trailer Test
Road tests were performed on a stretch of California’s infamous Grapevine (Interstate 5) on the same truck, with the same driver and the same load, at the same time of day and at same temperature. Starting with a nominal 78° ambient temperature, the operator pulled an 11,650 lb weight trailer with a 2018 Chevy Silverado 2500HD 6.6L diesel. Gross combined weight was 19,750 lbs. The rear differential was heated by maintaining a constant speed of speed of 55 mph up a 6% grade for 5 miles, ascending over 1,600’.
At the top of the 550 second hill climb, running the 3.9 quart stock differential cover, the lubricant temp was 205°. Filled with 7.5 quarts, the Mag-Hytec recorded 199° while the Banks filled with 4 quarts recorded 192.5°. Even with less lubricant, the Ram-Air cover controlled heat 2X better than the flat-back during the high horsepower hill climb!
From the crest to the end of the test, running 55 mph for 700 second at relatively constant elevation, the stock cover cooled from 205° to 195°. The Mag-Hytec cooled to 192.5° and 178.5° for Banks, a 4X improvement over the Mag-Hytec and by extension all other flat-back copies.
Chassis Dyno Testing: Heat Rejection — Sustained Power Test
This test was used to determine high load, steady state thermal management. Gale had originally requested a 90 minute, 250 hp test. Gale soon regretted that request. At 90 minutes the lubrication measured 316° and was still climbing. The intense test even resulted in the dyno catching on fire. After repairs were made, the test was revised to 60 minutes at 200 hp.
Testing was started after a 100° nominal temperature was achieved. Using a 2007 Dodge Ram 6.7L 3500 dually, the truck was brought 60 mph and loaded to 200 hp, typical of pulling a heavily loaded trailer up a 6% grade. Lubrication was changed between every test.
The equivalent of 60 MPH road speed air was directed under the truck’s belly using the Banks Wind Machine, aided by additional shop fans. Air damns were constructed to contain the airflow under the truck toward the rear differential.
At the end of the 60 minutes test, the lubrication temp was 289°, AFE was 261° or 28° cooler than stock. Banks was 228° or 61° less than stock. Banks outcooled AFE by 118% and by extension, all flatback covers.
Anemometer: Air Velocity
After affixing anemometers fore and aft of the rear differential, a dead zone was discovered. Like the wing of plane, the rear differential splits the air. At a road speed of 70 mph, air speed was measured at 32 MPH in front of the differential and 11 MPH 20" behind the differential. This indicated an area of dead air.
This low velocity dead zone extends as far out as 36" from the back face of the cover. No matter how deep the cooling fins are, they’re unable to adequately reject heat due to inadequate airflow over the surface of the fins.
This discovery resulted in the Ram-Air scoop concept. As the truck moves through the air, cool static air is forced into the Ram-Air scoops and directed 90° up and through the long, thin heat radiation fins.
Fuel Economy Testing Simulated City Driving
Fuel Economy was tested on the Mustang dyno using the OBD-II fuel flow rate and vehicle speed data, as well as the Banks emissions analyzer to measure fuel economy calculated from tailpipe emissions. The dyno was calibrated to simulate a 7,500 lb vehicle with an engine output of 30 HP required to maintain a 50 mph steady state speed. The truck was warmed to operating temperature then held at a constant 50 mph for a fixed length of time to procure an accurate average fuel consumption. The test was repeated for all covers as per their respective manufacturer’s fill level specifications.
At $3.50 per gallon of diesel, Banks owners will save $251 in fuel for every 100,000 miles driven as compared to stock. Flatback owners will spend approximately $447 in lost fuel economy over stock, enough money to buy another diff cover. Those upgrading from a flat-back design to a Banks cover can will see a $697 savings in fuel economy over their next 100,000 miles.
Doesn't look like the scoops are replaceable. I don't really see how they could be ripped off unless you did some serious off road driving or mudding. My truck won't be seeing anything more than a dirt road.
I wish they didn't put the scoops on there. I know they wanted to add buzz words like "ram air" to justify the $400 price but I don't like the idea of "breakaway" metal bits hanging off of the diff housing waiting to get snagged on stuff.
You also have to read their stats carefully. A lot of their big numbers are achieved by comparing it against the poorly designed flatback cover. The stock cover actually performs very well and doesn't cost $400....
You also have to read their stats carefully. A lot of their big numbers are achieved by comparing it against the poorly designed flatback cover. The stock cover actually performs very well and doesn't cost $400....
I find it funny that Banks did not include the cover in testing that is made by the axle mfg and costs 1/2 the price.
Attachments
https://www.dieselpowerproducts.com....com/p-13338-bd-power-rear-differential-cover-aa-14-115-03-18-ram-01-19-gm.aspx
The original "round back" cover.....
The original "round back" cover.....
Go look on YouTube on Banks channel for their series of tests on diff covers. Very informative from an engineering standpoint. Now granted they did these tests before making their own cover because they wanted to find out what worked and what didn't before designing theirs. Good videos
Sent from my HTC6545LVW using Tapatalk
Sent from my HTC6545LVW using Tapatalk
Well I have already put the Banks cover on but if I would have seen the AAM cover first back in March when I got the truck I might have gone that route. I would have definitely had it powder coated black though. I don't care for the straight aluminum look. Thanks for the information on the AAM cover and how to find it.
I'm curious if a sight glass can be added to the AAM cover. Banks does not sell theirs as a separate part. aFe sells their sight glass separately but I'm guessing the thread size won't work on a factory cover.
I found this sight glass: https://www.mscdirect.com/product/details/64829260
Which has the correct thread size based on this: Installation Parts and Kits: Vents, Drain/Fill Plugs | American Axle & Manufacturing | Aftermarket OE Parts
But the threads are a lot shorter than the factory fill plug...
I found this sight glass: https://www.mscdirect.com/product/details/64829260
Which has the correct thread size based on this: Installation Parts and Kits: Vents, Drain/Fill Plugs | American Axle & Manufacturing | Aftermarket OE Parts
But the threads are a lot shorter than the factory fill plug...
Good point about the level of the drain plug. Duh.
My AAM diff cover came in today. It looks pretty nice. As you can see this one doesn't have the flat spot below the drain plug. Different revision maybe...
Now I just need to decide on the color for powder coat. Matte black would be fine, but I might go with red to match my WCFab piping.
My AAM diff cover came in today. It looks pretty nice. As you can see this one doesn't have the flat spot below the drain plug. Different revision maybe...
Now I just need to decide on the color for powder coat. Matte black would be fine, but I might go with red to match my WCFab piping.
Attachments
Fresh off the lot and only just arrived, Banks engineers wasted little time getting the new 2020 GMC Sierra Denali on the lift for its initial once-over and 3D scan. As soon as that was done, the exhaust came off and fabrication had begun!
Here's the tentative list of Banks performance parts for the 2020 Duramax L5P: The 5" Zero-Backpressure Monster-Exhaust with SideKick™ tip will likely be the first part available followed by the Derringer tuner, Ram-Air cold air intake, Ram-Air diff cover, and intercooler.
It's no secret that the new Duramax 2500HD and 3500HD have a tow rating of up to 35,500 lbs putting the impressive 910 lb-ft of torque to good use. With that beefy tow rating comes new, heavy duty parts and better thermal management like an updated air intake system, huge 28" fan, improved radiator and intercooler as well as a new rear axle. After almost 19 years, GM engineers finally decided this was the year to update the axle housing to accommodate a giant 12" ring gear in the 3500HD. It's still a 14-bolt configuration but the pattern is a little different.
Here's the tentative list of Banks performance parts for the 2020 Duramax L5P: The 5" Zero-Backpressure Monster-Exhaust with SideKick™ tip will likely be the first part available followed by the Derringer tuner, Ram-Air cold air intake, Ram-Air diff cover, and intercooler.
It's no secret that the new Duramax 2500HD and 3500HD have a tow rating of up to 35,500 lbs putting the impressive 910 lb-ft of torque to good use. With that beefy tow rating comes new, heavy duty parts and better thermal management like an updated air intake system, huge 28" fan, improved radiator and intercooler as well as a new rear axle. After almost 19 years, GM engineers finally decided this was the year to update the axle housing to accommodate a giant 12" ring gear in the 3500HD. It's still a 14-bolt configuration but the pattern is a little different.
A year ago Banks starts this video on aftermarket rear diff covers. It takes a good month or two to get their research nailed down that flatback covers are worse than the stock cover. I found their research very interesting and sub'd to their site and link on this. Now comes the irritating part. They say they are gonna make their own cover, which we all know is gonna be WAY better than any aftermarket since they found allthe flaws and will also be better than the stock cover. I called Banks in early January and was told it's in manufacturing and will be released in the spring. Spring came and went and still nothing. I called out there again and hear that now it's now going to be released until late fall. Its spring time, my truck is out of storage and ready for towing season. I dont have time to wait. I scoured the internet looking for a finned AAM one and everyone was out of stock. I was about ready to give up and stumbled on a place in North Carolina. Send it! 2 days later I got it and took it to my powdercoater. I've got a bit less into the AAM one compared to the Banks one. They both keep the same capacity of fluid and it would have been interesting on the findings of the finned AAM vs Banks. Yes, there are 2 bolts missing. At the time of installation the company I got my stainless bolts from only had 12. So I took those and got it put on and put the other 2 in the next nite.
Attachments
Where did you get stainless bolts from? The Banks came with chrome plated and I work near the beach and think they might not hold up over time.
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