Differential Cover: Service and Repair

Removal

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.

1. Raise and support the vehicle.

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





2. 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

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.

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





2. 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 and ESE-M4G 195-A.

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.





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

CAUTION: For Traction-Lok(R) axles, first fill the rear axle with 118 ml. (4 oz.) of specified Ford Friction Modifier.

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





4. Fill the rear axle with 1.8 liters (3.75 pints) of Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2CI 97-A and install the filler plug.
5. Lower the vehicle.