Differential Cover: Service and Repair

Removal
1. Raise and support the vehicle.





2. Note: Empty the lubricant into a clean container for reuse.

Remove the differential housing cover.
1 Remove the 10 differential housing cover bolts and drain the lubricant from the rear axle housing.
2 Remove the differential housing cover.

Installation

1. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the rear axle and the differential housing cover.





2. Apply a new continuous bead of sealant of the specified thickness to the differential housing cover.
- Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A.





3. Note: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has properly cured.

Install the differential housing cover.
1 Install the differential housing cover.
2 Install the 10 differential housing cover bolts.





4. CAUTION: For Traction-Lok axles, before filling the rear axle with lubricant, first fill the rear axle with 118 ml (4 oz) of Ford Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.

Note: Service refill capacities are determined by filling the rear axle with the specified lubricant to the level shown in the illustration.

Fill the rear axle with 2.4 liters (5 pints) of SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2('197-A and install the filler plug.
5. Lower the vehicle.