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Differential Housing Cover: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Clean the mounting surface on the differential housing cover and the differential housing with a suitable solvent to remove all traces of oil film.
    CAUTION: The differential housing cover uses silicone rubber sealant material as a gasket. Install the differential housing cover within 15 minutes of applying the silicone or it will be necessary to apply new sealant.
    Fig 1: Applying A Continuous Bead Of Silicone To Differential Housing Cover Mounting Surface
    G02760412Courtesy of FORD MOTOR CO.
  1. Apply a continuous bead of silicone to the differential housing cover mounting surface.
  2. Assemble two bolts into the differential housing cover at the eight o'clock and two o'clock positions. Using these two bolts as a guide, position the differential housing cover on the differential housing.
  3. Install the remaining bolts. Tighten the bolts alternately and evenly.
    • Tighten Grade 5 bolts to 47 Nm (35 lb-ft).
    • Tighten Grade 8 bolts to 61 Nm (45 lb-ft).
    Fig 2: Installing Differential Housing Cover Bolts
    G02760413Courtesy of FORD MOTOR CO.
    4. CAUTION: Allow 1-hour cure time before filling the axle with the correct amount of specified lubricant and operating the vehicle.
  4. Fill the differential housing with the specified type and amount of lubricant. For additional information, refer to SPECIFICATIONS .
  5. Lower the vehicle.
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