This procedure drains and refills the front differential fluid on a 4WD 2011-2014 Ford F-150 with 3.5L EcoBoost engine to maintain proper lubrication and extend differential life.

Warnings

Tools required

Parts

• Front differential cover gasket × 1 — Use OEM specification
• Magnetic drain plug (if equipped) × 1 — Reuse unless damaged

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. If vehicle was recently driven, allow differential to cool for at least 30 minutes
4. Raise front of vehicle and support securely on jack stands rated for vehicle weight
5. Verify vehicle is stable before working underneath
6. Remove front skid plate if equipped to access differential cover

Procedure

1. 1

   Locate and clean differential cover
   Locate the front differential cover on the rear side of the differential housing. Use a wire brush to clean around the cover bolts and drain area to prevent contamination when opening. The cover is typically oval-shaped and secured by 10-12 bolts.
2. 2

   Position drain pan and loosen cover bolts
   Position the drain pan directly beneath the differential cover. Begin loosening all differential cover bolts in a crisscross pattern, but do not remove them completely yet. This allows you to control the fluid drainage.
3. 3

   Remove lower cover bolts and drain fluid
   Remove the lower cover bolts first, leaving the upper bolts partially threaded. Carefully pry the bottom of the cover away from the housing to create a gap for fluid to drain. Once flow slows, remove the remaining bolts and carefully remove the cover. Allow all fluid to drain completely into the pan.
   ⚠Fluid may drain quickly once cover is separated. Keep hands clear of stream and ensure drain pan is positioned to catch all fluid.
4. 4

   Inspect differential components
   With the cover removed, inspect the interior of the differential for metal shavings, debris, or unusual wear. Check the magnetic drain plug (if equipped) for excessive metal particles. Minor fine particles are normal, but large chunks or excessive material may indicate internal wear. Inspect the ring and pinion gears visually for obvious damage.
5. 5

   Clean cover and mating surfaces
   Thoroughly clean the differential cover using a scraper and shop rags. Remove all old gasket material from both the cover and the differential housing mating surface. Ensure surfaces are completely clean and dry. Clean the magnetic drain plug if equipped and inspect threads for damage.
6. 6

   Install new gasket and position cover
   Place the new gasket onto the differential housing, aligning all bolt holes. Some gaskets may have an adhesive backing to hold them in place. Position the differential cover onto the gasket, ensuring proper alignment of all bolt holes. Insert all cover bolts finger-tight.
7. 7

   Torque differential cover bolts
   Using a torque wrench, tighten the differential cover bolts in a crisscross pattern to ensure even gasket compression and prevent leaks. Start from the center bolts and work outward.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
8. 8

   Refill differential with gear oil
   Locate the fill plug on the front or side of the differential housing. Remove the fill plug and use a fluid transfer pump or squeeze bottle to add 75W-90 GL-5 gear oil. Fill until fluid reaches the bottom of the fill plug hole (fluid should just begin to seep out). Install and tighten the fill plug securely.
   ℹ️Add fluid slowly to prevent overflow. The front differential holds approximately 1.5 quarts.
9. 9

   Check for leaks and reinstall skid plate
   Wipe down the differential cover and surrounding area with a clean rag. Inspect the cover gasket seal for any signs of leakage. If equipped, reinstall the front skid plate using the original mounting bolts.

Reassembly

1. Lower vehicle from jack stands carefully
2. Remove wheel chocks
3. Dispose of used gear oil at an approved recycling facility
4. Clean all tools and work area

Verification

• Start vehicle and allow to idle briefly, then shut off
• Re-inspect differential cover gasket area for any signs of leakage
• Test drive vehicle for 5-10 minutes, including turns in both directions to circulate fluid
• After test drive, re-inspect cover and fill plug for leaks while vehicle is warm
• Check fluid level at fill plug after test drive; top off if necessary

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