This procedure drains and refills the front differential fluid on a 4WD 2011-2014 Ford F-150 with 5.0L Coyote engine to maintain proper lubrication and extend differential life.

Warnings

Tools required

Parts

• Front differential cover gasket × 1 — Use OEM specification or Felpro RDS 55468
• RTV silicone sealant (if gasket not used) × 1 — Motorcraft TA-357 or equivalent

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow differential to cool if vehicle was recently driven
4. Raise front of vehicle with floor jack and support securely on jack stands at frame rails
5. Ensure adequate clearance to access front differential cover from underneath

Procedure

1. 1

   Locate and clean differential cover
   Position yourself under the front of the vehicle. Locate the front differential cover on the rear face of the front differential assembly (center of front axle). Clean the area around the cover bolts with a wire brush to remove dirt and debris before loosening.
2. 2

   Loosen differential cover bolts
   Using a 3/8" drive ratchet with appropriate socket, loosen all differential cover bolts approximately 2-3 turns but do not remove them yet. Loosen the top bolts last to allow fluid to drain from the bottom edge first.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
3. 3

   Drain differential fluid
   Position drain pan beneath the differential cover. Carefully remove the lower bolts first, allowing the cover to tilt downward and fluid to drain into the pan. Once fluid flow slows, remove remaining bolts and carefully remove the cover. Be prepared for additional fluid release. Allow to drain completely for 5-10 minutes.
   ⚠Fluid will spill quickly when lower bolts are removed. Ensure drain pan is properly positioned.
4. 4

   Inspect differential components
   With cover removed, visually inspect the ring and pinion gears through the opening for excessive wear, metal particles, or damage. Check the magnetic drain plug (if equipped on cover) for metal shavings. Fine metallic dust is normal, but chunks or excessive material indicate potential problems requiring further inspection.
5. 5

   Clean cover and mating surface
   Thoroughly clean the differential cover using a gasket scraper to remove all old gasket material or RTV sealant. Clean the differential housing mating surface as well, ensuring both surfaces are completely free of old gasket material, RTV, oil residue, and debris. Wipe clean with shop rags.
6. 6

   Prepare new gasket or apply RTV
   If using a gasket: position the new gasket on the differential cover, aligning all bolt holes. If using RTV sealant instead: apply a continuous 1/8" bead of RTV around the cover bolt hole perimeter, circling each bolt hole. Allow RTV to set for 5-10 minutes if specified by sealant manufacturer.
   ℹ️Do not use both gasket and RTV together unless specifically required by Ford for this application.
7. 7

   Install differential cover
   Carefully position the cover with gasket or RTV onto the differential housing, aligning all bolt holes. Insert all bolts finger-tight to hold the cover in place. Ensure the cover is seated evenly against the housing before proceeding.
8. 8

   Torque differential cover bolts
   Using a torque wrench, tighten the differential cover bolts in a criss-cross pattern to 35.0 Nm (26 lb-ft). Start with the center bolts and work outward to ensure even gasket compression and prevent cover warping. Make multiple passes, gradually increasing torque to final specification.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
9. 9

   Fill differential with gear oil
   Locate the fill plug on the front or side of the differential housing (typically a square or hex plug). Remove the fill plug using appropriate tool. Using a fluid transfer pump or squeeze bottle, add 75W-90 GL-5 gear oil through the fill hole until fluid begins to drip from the fill hole opening. The capacity is approximately 1.5 quarts, but fill to the bottom of the fill hole regardless of measured quantity.
   ℹ️Fill until oil reaches the bottom of the fill plug hole. Overfilling can cause seal damage and leaks.
10. 10

    Reinstall fill plug and check for leaks
    Clean the fill plug threads and reinstall, tightening securely by hand plus 1/4 turn. Wipe down the differential cover area with clean rags. Inspect the cover gasket/RTV seal for any signs of immediate leakage.
11. 11

    Lower vehicle and perform final checks
    Remove jack stands and carefully lower the vehicle to the ground. Start the engine and shift through all transmission gears (including 4WD if applicable) while stationary with brakes applied. Turn engine off and re-inspect differential cover for leaks.

Reassembly

1. If RTV was used, allow 24 hours cure time before driving if possible, or minimum 1 hour before test driving
2. Dispose of used gear oil properly at a recycling center or auto parts store

Verification

• Check for leaks around differential cover gasket after first test drive
• Re-check fluid level at fill plug after 50-100 miles of driving
• Monitor for unusual noises from front differential during turns and acceleration
• Inspect under vehicle for signs of leakage after first week of driving

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