Differential Housing Cover: Installation

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

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.
Apply a new continuous bead of sealant to the differential housing cover.

Fig 1: Applying Continuous Bead Of Sealant To Differential Housing Cover
Courtesy of FORD MOTOR CO.

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.
  
  Fig 2: Identifying Tightening Torque Of Differential Housing Cover Bolts
  Courtesy of FORD MOTOR CO.

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

NOTE: Service refill capacities are determined by filling the rear axle to the level shown.

Fig 3: Identifying Tightening Torque Of Filler Plug

Courtesy of FORD MOTOR CO.

Fill the rear axle with 2.4 liters (5.5 pints) of rear axle lubricant and install the filler plug.
Lower the vehicle.