Replace the rear differential cover gasket to repair leaks or perform maintenance on the 2011-2014 Ford F-150 4WD with 5.0L V8 engine.

Warnings

Tools required

Parts

• Rear differential cover gasket × 1 — Use OEM specification or Motorcraft BR-3Z-4033-B
• RTV silicone sealant (optional) × 1 — Use per manufacturer preference

Fluids

• Motorcraft 75W-140 Synthetic Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels to prevent vehicle movement
3. Allow differential to cool completely if recently driven (at least 1 hour)
4. Raise rear of vehicle using floor jack and support securely on jack stands at frame rail points
5. Ensure adequate working clearance under vehicle
6. Position drain pan under rear differential cover

Procedure

1. 1

   Drain differential fluid
   Locate the rear differential cover on the center of the rear axle. Using a 3/8" drive ratchet and appropriate socket, loosen all differential cover bolts by 2-3 turns but do not remove completely. Starting with the lower bolts, gradually loosen them further to allow fluid to drain into the pan. Once draining slows, remove all bolts and carefully pry the cover away from the housing using a gasket scraper. Allow all fluid to drain completely.
2. 2

   Remove differential cover
   Once fluid has fully drained, remove the differential cover completely and set aside. Inspect the interior of the differential housing for metal shavings or debris on the magnetic drain plug (if equipped). Minor fine particles are normal, but large chunks or excessive material may indicate wear issues requiring further inspection.
3. 3

   Clean differential cover
   Thoroughly clean the differential cover using a wire brush and brake cleaner. Remove all old gasket material from the cover mating surface using a gasket scraper, being careful not to gouge or scratch the aluminum surface. Clean the magnetic drain area if equipped. Wipe down with a clean shop rag and ensure the surface is completely clean and dry.
4. 4

   Clean differential housing mating surface
   Using a gasket scraper, carefully remove all old gasket material from the differential housing mating surface. Take care not to allow debris to fall into the differential housing; use shop rags to catch material. Clean the surface thoroughly with brake cleaner and wipe dry. Inspect the mating surface for damage or warping that could prevent proper sealing.
5. 5

   Install new gasket
   Position the new differential cover gasket on the cover, aligning all bolt holes. If using RTV sealant per manufacturer preference, apply a thin bead to one side of the gasket or to the housing mating surface per gasket instructions. Some gaskets are designed to be installed dry; verify installation method for your specific gasket type.
6. 6

   Reinstall differential cover
   Carefully position the differential cover with gasket onto the housing, ensuring the gasket remains properly aligned. Install all differential cover bolts by hand, threading them in a crisscross pattern to ensure even gasket compression. Verify all bolts are started properly before tightening any.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
7. 7

   Torque cover bolts
   Using a torque wrench, tighten the differential cover bolts in a crisscross or star pattern to ensure even gasket compression. Torque all bolts to 35.0 Nm (26.0 lb-ft). Make a second pass in the same pattern to verify all bolts are properly torqued.
   Torque spec

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

   Refill differential with gear oil
   Locate the differential fill plug on the front of the differential housing (driver side, above axle tube level). Remove the fill plug before beginning to ensure it is not seized. Using a fluid transfer pump or funnel with extension hose, add Motorcraft 75W-140 Synthetic Gear Oil through the fill hole. Fill until fluid begins to seep from the fill hole (approximately 2.0 quarts). The proper level is at the bottom of the fill plug hole when vehicle is level.
9. 9

   Reinstall fill plug
   Clean the fill plug threads and reinstall, tightening securely by hand then snugging with a ratchet. Wipe away any excess gear oil from the differential housing exterior.
10. 10

    Inspect for leaks
    Carefully inspect the entire perimeter of the differential cover gasket for any signs of leakage. Wipe the area clean with a shop rag. Lower the vehicle from jack stands and remove support equipment.

Reassembly

1. If RTV sealant was used, allow to cure per manufacturer instructions before driving (typically 1-2 hours)
2. Dispose of used gear oil properly at a recycling facility; do not pour down drains
3. Keep drain pan under vehicle for 24 hours to catch any potential leaks

Verification

• Start engine and let idle briefly, then check for leaks around differential cover gasket
• Test drive vehicle for 5-10 miles, allowing differential to reach operating temperature
• Re-inspect differential cover gasket area for any signs of seepage or leaks
• After 50-100 miles of driving, recheck fluid level at fill plug and top off if necessary
• Monitor for leaks during first week of operation

More procedures for this vehicle