Differential Housing Cover: Installation

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

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.

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

Fig 1: Applying Bead Of Sealant To Differential Housing Cover

Courtesy of FORD MOTOR CO.

Apply a continuous bead of silicone gasket and sealer to the differential housing cover.

NOTE: If possible, allow at least 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. If equipped, install the axle guard.
2. Install the bolts.
  - Tighten the bolts in a star pattern.
  - Tighten to 45 Nm (33 lb-ft).
3. Install the axle tag bolt.
  - Tighten to 31 Nm (23 lb-ft).
    
    Fig 2: Installing Differential Housing Cover
    Courtesy of FORD MOTOR CO.
    
    Fig 3: Installing Axle Tag Bolt
    Courtesy of FORD MOTOR CO.

CAUTION: For Traction-Lok® axles, first fill the rear axle with 118 ml (4 oz) of additive friction modifier.

CAUTION: Before attempting to remove the axle fill plug, make sure the tool recess is free of foreign material which may keep the tool from fully engaging the plug. Clean the recess with a small screwdriver or similar tool. Make sure the tool can be fully inserted into the recess before attempting to remove the plug.

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 2.37 liters (5.0 pints) of lubricant and install the fill plug.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 4: Identifying Rear Axle Capacities With Specification
  Courtesy of FORD MOTOR CO.

WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .

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

Fig 5: Locating Air Suspension Service Switch

Courtesy of FORD MOTOR CO.

Lower the vehicle.