Differential Cover: Service and Repair

Differential Housing Cover
Removal

1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

Raise and support the vehicle.

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





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

Installation

1. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the silicone sealant. Cover the inside of the rear axle prior to cleaning the machined surface to prevent contamination.

Clean the gasket mating surfaces.

2. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.





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

3. NOTE: If possible, allow one hour before filling the axle with lubricant to allow the silicone sealant to cure.





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

4. CAUTION: For Traction-Lok (R) axles, first fill the rear axle with 118 ml. (4 oz.) of Additive 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 1.8 liters (3.75 pints) of lubricant and install the fill plug
- Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

5. NOTE: If equipped with air suspension, reactivate the system.

Lower the vehicle.