Differential Cover: Service and Repair

REMOVAL
1. Raise vehicle on a hoist.





2. Support rear axle housing and remove rear axle differential rear insulator-to-crossmember retaining nuts.





3. Position drain pan under rear axle housing. Remove fill plug with 3/8-inch flex handle and remove axle housing cover-to-housing retaining bolts.





4. Remove rear axle housing cover.





INSTALLATION
1. Clean sealing surfaces and groove in axle housing cover.

NOTE: Make sure rear axle housing vent and vent hose are not plugged. When axle housing cover is installed, the open end of vent hose fits into middle hole in RH rail of crossmember.





2. Apply a continuous bead of Silicone Rubber D6AZ-19562-AA or-BA or equivalent meeting Ford specifications ESE-M4G195-A or ESB-M4G92-A to groove in axle housing cover.

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

NOTE: Axle housing cover assembly must be installed within 15 minutes of application of the silicone or new sealant must be applied.

3. Position axle housing cover and install retaining bolts.

CAUTION: Tighten the axle housing cover bolts in a crosswise pattern to prevent distortion of axle housing cover.

4. Place service identification tag in the 12 o'clock position. Tighten to 27-37 Nm (20-27 ft. lbs.).
5. Install rear axle differential rear insulator to crossmember nuts. Tighten to 108-136 Nm (80-100ft. lbs.)).
6. Fill rear axle housing with SAE 80W-90; Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A to 6.35 mm (1/4 inch) below the bottom of filler hole.





7. Install oil filler plug. Tighten to 20-41 Nm (15-30 ft. lbs.).
8. Lower vehicle.