Originally Posted By: Bluestream
75W140 will give you some protection in high heat high load conditions. It will also cost you 1% in fuel economy, and the axel will run a bit hotter. A 4500lb load is nothing to sneeze at, and if it were me I would be running the 75W140 in that setup. Ford dealer will say the same.
Explorers have 75W140 as FF with 3:73 ot 4:10 gear ratios or with Trac-Lok diff. I am useing redline 75W140 in my Explorer with 4:10 gears, and I only do light towing.
I don't know if the synthetics climb the gears well or not, but they seem to be FF in any heavy-duty application.
Bluestream is right about the 140 costing fuel economy and running hotter. I had to switch from a syn 75W140 to a "nuthin'-special" mineral 80W90 because the new limited slip I got requires it. My diff temp went DOWN 10 degrees, despite new bearings on the carrier, slightly tighter setup, and a much warmer day on the return trip.
As to fuel economy, I can't definitively say much... if it were 1%, that would be hard to pull out of the normal variable "noise" that occurs with "normal" methods of MPG testing. Seems like there's been a slight uptick on mine and it could be more significant looked at cumulatively over a long period.
After a fair bit of fooling around, I have come to the conclusion that my diff oil viscosity choices should base on oil temperature. Therefore, job-one for is to install a diff temp gauge and monitor it under all operating conditions. Since I run a small farm, that includes hauling and towing. There are diff temp gauges on both my working trucks.... both Fords and both 10.25 axles. Both now have Mag-Hytec covers, which have a bung for a temp sender, however I welded in a bung onto the original steel cover of the older truck before the Mag-Hytec was installed. AutoMeter sells those bungs for a coupla bucks each and you can use any kind of temp gauge, though I know both AutoMeter and Isspro make some marked "Diff Temp." A tip: On a one wire gauge, run a ground wire from the axle to the chassis because there is not always a great ground through the springs or driveshaft.
My own criteria for the viscosity choice is whether or not the diff oil temp exceeds the 212F (100C) degree threshold significantly or long term. AYK, 212F is the point at which the hot viscosity measurement is taken. Using a temp vs viscosity chart (good ol' Widman has one on his site), I want to keep the oil at no less than about the bottom of the 90 grade range, around 14 cSt at whatever my highest sustained temp is. I don't worry about an occasional short spike unless it's well over 250F. Most oils can handle that for a few minutes. If an axle runs at a sustained 250F towing, however, a 90 grade could be down in the 75-80 grade area. That's not immediately harmful either but long term it could be, so that would dictate a 110 or 140 grade to maintain that minimum viscosity.
You have to monitor your oil temps for a while to rack up the data. I have compared mine with other guys as pedantic as me and I am surprised at both how high and how low diff temps run on various trucks. I have learned that the Mag-Hytec cover knocks an average of about 15 degrees off diff oil temp. I also learned that a good syn oil can knock an honest 10F off the same viscosity grade of mineral oil. Knowing both of these things has shown me that my truck can safely run a 90 grade for whatever increase there is in fuel economy day to day with no worries about dropping out of the 90 grade.
My overall logic is that if you tow 5 percent of the time, it makes no sense to hurt yourself MPG-wise by running a heavier grade oil than you need.... even if that hurt is only 1%. If you live in a cold climate that hit could be more in the winter. If the oil temp exceed 212F towing for five minutes going up a hill, no biggie. It will cool back down. It's possible that you might see some overly high temps towing only occasionally, so you might have to take the hit in the daily driving department and use a heavier oil to preserve the axle. I contend, however, that a diff temp gauge allows you to monitor and make adjustments to the situation to keep that temp lower (see the list below). Also, a higher capacity, finned cover might be enough to maintain those lower maximum temps, though it also keeps the oil cooler longer.
Assuming demonstrated overly high temps, I've crunched the numbers a couple of ways and using 1% drop of economy, it comes out somewhat cheaper to just use the heavier oil than to spend a lot of money on covers and such, but that would depend on how much hit there truly is on fuel economy and the cost of fuel. I strongly believe the diff temp gauge is a worthwhile addition for any truck that tows.
Some general things I have learned:
1) At a given load, a larger ring gear axle will run cooler than a smaller (more tooth contact to spread the load)
2) At a given load, a lower ratio (4.10. 4.56:1 etc) will run hotter than a lower (3.23-3.55:1, etc, ... more hypoid action creating more heat)
3) At the same viscosity a syn oil will run about 10 F cooler than a mineral, EXCEPT mineral oils with special additives. I used a LE oil (LE607), which was a straight 90 but one that had lots of a proprietary moly-like additive that surprised my by running as cool as a well-known syn. The Chevron ESI oils are said to exhibit similar characteristics, though I have not seen that demonstrated personally.
4) Fluid friction from an oil heavier than needed causes the oil to run hotter.
5) At any given load, the faster you go, the hotter the diff runs. SOme of that is load due to windage but some comes from the diff itself... that hypoind sliding action occurring more often and heating theoil faster.
6) A higher viscosity oil than you need for the temp range costs fuel economy.