Front Differential

This procedure covers the removal and replacement of the front differential assembly on a 2011-2014 Ford F-150 with 3.5L EcoBoost engine and 4WD.

Warnings

Tools required

Parts

• Front differential assembly × 1 — Use OEM specification
• Differential cover gasket × 1 — Use OEM specification
• Differential mounting bushings (if worn) × 2 — Use OEM specification
• CV joint bolts × 12 — Replace if damaged
• Axle nut cotter pins × 2 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable
3. Raise front of vehicle and support securely on jack stands at frame rails
4. Remove both front wheels
5. Place drain pan under front differential
6. Allow differential to cool if vehicle was recently operated

Procedure

1. 1

   Drain differential fluid
   Remove the differential cover bolts in a crisscross pattern, loosening one side first to allow fluid to drain in a controlled manner. Once drained, remove all cover bolts and the cover. Clean the mating surfaces with a wire brush and inspect for metal shavings or debris that may indicate internal damage.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
2. 2

   Mark and disconnect front driveshaft
   Use a marker or paint pen to mark the relationship between the front driveshaft yoke and the differential pinion flange. Remove the four U-joint strap bolts. Support the driveshaft and separate it from the differential. Secure the driveshaft out of the way with wire or have an assistant support it.
   ℹ️Do not allow the driveshaft to hang freely as this can damage the CV joint at the transfer case end.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
3. 3

   Remove axle shaft nuts
   Remove the cotter pins or unstake the axle nuts on both front axle shafts. Use a breaker bar to loosen and remove the 36mm axle nuts while having an assistant apply the brakes to prevent wheel hub rotation. Remove and discard the axle nuts and cotter pins.
   ⚠Axle nuts are torqued to 250 Nm. Significant force is required for removal.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
4. 4

   Disconnect CV axles from differential
   Remove the six CV joint bolts on each side (12 total) that connect the inner CV joints to the differential output flanges. Support the axle shafts and carefully separate them from the differential. Secure the axle shafts to the suspension or frame using wire to prevent damage to the outer CV joints and boots.
   ⚠Do not allow axle shafts to hang unsupported as this can damage CV joints and boots.
   Torque spec

   CV Bolts70 Nm (52 lb-ft)
5. 5

   Disconnect electrical connectors
   Locate and disconnect the front differential electronic locking actuator connector if equipped with electronic locking differential. Press the tab and pull the connector straight out. Secure the connector out of the way.
6. 6

   Support differential assembly
   Position a transmission jack or suitable support fixture under the front differential housing. Raise the jack until it just contacts the differential and secures it in place. Ensure the differential is stable and centered on the jack saddle.
   ⚠️The differential must be properly supported before removing mounting bolts. An unsupported differential can fall and cause serious injury.
7. 7

   Remove differential mounting bolts
   Locate the differential mounting bolts that secure the differential to the front subframe. There are typically four mounting bolts. Remove all mounting bolts while maintaining support with the transmission jack. Note the position and orientation of any mounting brackets or bushings.
   ⚠Keep hands and body clear of the differential as mounting bolts are removed in case it shifts position.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Lower and remove differential
   Carefully lower the transmission jack while guiding the differential assembly down and out of the vehicle. Maneuver the differential to clear the subframe and any suspension components. Remove the differential from under the vehicle and place it on a workbench. Inspect mounting bushings for wear and replace if necessary.
9. 9

   Prepare and install replacement differential
   Transfer any necessary components from the old differential to the replacement unit. Install new mounting bushings if required. Fill the new differential with the specified amount of 75W-90 GL-5 gear oil (1.5 quarts) through the fill hole. Position the replacement differential on the transmission jack and carefully raise it into position, aligning the mounting holes with the subframe.
10. 10

    Install mounting bolts
    Install all four differential mounting bolts with any brackets in their original positions. Start all bolts by hand to ensure proper thread engagement. Torque the mounting bolts to specification in a crisscross pattern.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
11. 11

    Connect CV axles to differential
    Remove the wire securing the axle shafts. Align the inner CV joint flanges with the differential output flanges. Install new CV joint bolts if originals are damaged. Install all six bolts per side and torque to specification in a star pattern.
    Torque spec

    CV Bolts70 Nm (52 lb-ft)
12. 12

    Reconnect front driveshaft
    Align the index marks made during disassembly on the driveshaft yoke and differential pinion flange. Install the U-joint strap bolts and torque evenly to specification to avoid distorting the bearing caps.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)
13. 13

    Install axle nuts
    Install new axle nuts on both front axle shafts. Have an assistant apply the brakes while torquing the axle nuts to specification. Install new cotter pins through the castle nut slots or stake the nut as per original equipment specification.
    ℹ️Never reuse old axle nuts or cotter pins. Always install new fasteners.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
14. 14

    Install differential cover
    Clean all old gasket material from the differential cover and housing mating surface. Install a new differential cover gasket. Position the cover and install all bolts hand-tight. Torque the differential cover bolts to specification in a crisscross pattern to ensure even gasket compression.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
15. 15

    Reinstall wheels and final checks
    Reconnect the electronic locking differential connector if equipped. Install both front wheels and hand-tighten lug nuts. Lower the vehicle to the ground. Torque wheel lug nuts to specification in a star pattern. Reconnect the negative battery cable.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Verify all electrical connectors are properly seated and secured
2. Double-check that all fasteners have been installed and torqued to specification
3. Verify the differential is properly filled with 1.5 quarts of 75W-90 GL-5 gear oil

Verification

• Start the engine and verify no warning lights are illuminated on the instrument cluster
• Test drive the vehicle in 4WD mode at low speed in a safe area, making several turns in both directions to ensure proper differential operation
• Check for any unusual noises, vibrations, or fluid leaks from the differential area
• Verify 4WD engagement and disengagement functions properly if equipped with electronic locking differential
• After test drive, raise vehicle and inspect for any fluid leaks around the differential cover and axle connections
• Check differential fluid level and top off if necessary

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