This procedure drains and refills the rear differential with fresh synthetic gear oil, ensuring proper lubrication of the ring and pinion gears in the 2011-2014 Ford F-150 4WD.

Warnings

Tools required

Parts

• Rear differential cover gasket × 1 — Motorcraft RG-6015 or equivalent
• RTV silicone gasket maker (if not using preformed gasket) × 1 — Motorcraft TA-31 or equivalent

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks in front of front tires
3. Raise rear of vehicle and support securely on jack stands at frame contact points
4. Verify rear differential is cool to the touch before beginning work
5. Locate differential cover at rear of axle housing - it is a large oval or rectangular cover with 10-12 bolts
6. Clean exterior of differential cover and surrounding area to prevent contamination

Procedure

1. 1

   Loosen differential cover bolts
   Using a 13mm socket, loosen all differential cover bolts approximately 2-3 turns, but do not remove them completely. Start at the top bolts and work around the cover in a crisscross pattern to prevent warping.
2. 2

   Remove upper bolts and begin draining
   Position drain pan directly beneath the differential cover. Remove the upper bolts first, then carefully loosen and remove the lower bolts. The cover will begin to leak as you loosen the lower bolts. Be prepared for fluid to flow out. Carefully pry the cover away from the housing at the bottom edge to allow fluid to drain.
   ⚠Gear oil will flow out quickly once the cover seal breaks. Keep drain pan positioned to catch all fluid.
3. 3

   Remove differential cover
   Once fluid has drained to a slow drip, fully remove the differential cover. Use a rubber mallet to gently tap the cover if it is stuck to the housing. Tilt the cover to drain remaining fluid into the drain pan.
4. 4

   Inspect differential internals
   With the cover removed, visually inspect the ring gear, pinion gear, and differential bearings. Look for excessive metal shavings or particles in the old fluid or on the magnetic drain plug (if equipped). A small amount of fine metallic residue is normal, but large chunks or excessive debris indicate wear.
   ℹ️If you find large metal chunks, broken teeth, or excessive wear, do not proceed with fluid change. The differential requires professional inspection.
5. 5

   Clean differential cover and housing
   Using a gasket scraper or plastic scraper, carefully remove all old gasket material from both the differential cover and the axle housing mating surface. Be careful not to gouge the aluminum surfaces. Clean both surfaces with shop rags until completely clean and dry. If equipped with a magnetic drain plug, wipe it clean of all metal particles.
6. 6

   Prepare new gasket
   If using a preformed gasket, position it on the differential cover. If using RTV silicone, apply a continuous 3-4mm bead around the inside of the bolt holes on the cover, making sure to circle around each bolt hole. Allow RTV to set for 5-10 minutes if specified by manufacturer.
7. 7

   Install differential cover
   Carefully position the differential cover with gasket onto the axle housing. Insert all bolts by hand, starting with the top bolts and working around the cover. Thread all bolts 3-4 turns by hand before tightening any of them to ensure proper alignment.
8. 8

   Torque differential cover bolts
   Using a torque wrench and 13mm socket, tighten the differential cover bolts in a crisscross pattern to 35 Nm (26 lb-ft). Start with the center bolts and work outward. Make at least two complete passes around the cover to ensure even torque distribution and proper gasket compression.
   ⚠Do not overtighten cover bolts as this can warp the cover and cause leaks. Use a torque wrench for proper specifications.
   Torque spec

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

   Refill differential with gear oil
   Locate the fill plug on the front face of the differential housing (usually requires a 3/8" ratchet or 10mm hex key). Remove the fill plug. Using a fluid pump, fill the differential with 2.0 quarts of Motorcraft 75W-140 synthetic gear oil through the fill hole. Oil should reach the bottom of the fill hole and may begin to seep out. If your differential has a limited-slip or electronic locking feature, add the appropriate friction modifier as specified on the differential identification tag.
10. 10

    Reinstall fill plug and lower vehicle
    Reinstall the fill plug and tighten securely by hand, then give it an additional 1/4 turn with the ratchet. Wipe away any excess oil from the differential housing. Lower the vehicle from the jack stands and remove wheel chocks.

Reassembly

1. If RTV silicone was used, allow at least 1 hour cure time before driving the vehicle
2. Check for leaks around the differential cover after the first short drive
3. Dispose of used gear oil at an appropriate recycling facility

Verification

• Start the engine and allow it to idle for 1-2 minutes
• Take a short test drive (5-10 minutes) to circulate the new fluid
• Inspect the differential cover for any signs of leakage around the gasket
• Check fluid level at the fill plug - fluid should be at or just below the bottom of the fill hole opening
• Listen for any unusual noises from the rear axle during acceleration and deceleration

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