Differential Cover: Service and Repair

Removal
1. Raise and support the vehicle.





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

Installation

1. CAUTION: Make sure the machined surface on the rear axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. To prevent contamination, cover the inside of the rear axle prior to cleaning the machined surface.

Clean the rear axle housing and the differential housing cover gasket mating surfaces.





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

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





3. Note: If possible, allow one hour before filling the axle with lubricant to make sure the silicone sealant has cured.

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





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

Note: In-vehicle repair refill capacities are determined by filling the rear axle to the level shown.

Fill the rear axle.
- For vehicles with 4.0L SOHC and 4.0L EI with Traction-Lok rear axles and 5.0L, use 2.4 liters (5.5 pints) of SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-1 9580-B or equivalent meeting Ford specification WSL-M2C192-A, and install the filler plug
- For vehicles with 4.0L SOHC and 4.0L EI with conventional rear axles, use 2.4 liters (5.5 pints) of SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
5. Lower the vehicle.