Complete disassembly, inspection, and rebuild of the front differential assembly including replacement of bearings, seals, and gear set as needed on a 2011-2014 Ford F-150 4WD with 5.0L V8.

Warnings

Tools required

Parts

• Front differential rebuild kit (bearings, seals, shims) × 1 — Use OEM specification
• Ring and pinion gear set (if worn) × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Axle seals × 2 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Motorcraft TA-31 or equivalent
• Drain plug washer × 1 — Use OEM specification
• Cotter pins for axle nuts × 2 — Use OEM specification
• Crush sleeve (if replacing pinion) × 1 — Use OEM specification
• Thread locker × 1 — Loctite 242 or equivalent

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 on jack stands at frame rails
4. Remove front wheels using appropriate socket
5. Place drain pan under differential
6. Mark driveshaft and companion flange orientation for reassembly
7. Take photos of all components before disassembly for reference

Procedure

1. 1

   Remove CV axles and driveshaft
   Remove cotter pins and loosen axle nuts (do not remove yet). Remove CV axle-to-differential flange bolts on both sides. Disconnect front driveshaft by removing U-joint strap bolts. Support driveshaft and remove from companion flange. Pull CV axles from hubs and support out of the way.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)

   CV Bolts76 Nm (56 lb-ft)

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
2. 2

   Drain differential and remove cover
   Remove drain plug and allow gear oil to fully drain into pan. Once drained, remove differential cover bolts in a crisscross pattern. Carefully pry cover off and clean all old RTV from cover and housing surfaces. Inspect drained oil for metal particles indicating wear.
   ⚠Gear oil may still be warm. Excessive metal debris in oil indicates internal damage.
   Torque spec

   Drain Plug51 Nm (38 lb-ft)

   Cover Bolts42 Nm (31 lb-ft)
3. 3

   Mark and remove bearing caps
   Mark bearing caps and housing with alignment marks for proper reassembly orientation. Remove bearing cap bolts and carefully remove bearing caps. Note the position of any shims behind the caps and keep them with their respective caps.
   ⚠Bearing caps are matched to the housing and must be reinstalled in original positions.
4. 4

   Remove carrier assembly
   Carefully pry carrier assembly from housing using pry points. Remove differential carrier with ring gear attached. Place on clean work surface. If available, use a case spreader tool to make removal easier. Remove any side bearing shims and label for their respective sides.
   ℹ️Keep all shims organized by location as they determine carrier bearing preload and ring gear position.
5. 5

   Disassemble carrier and remove ring gear
   Mark ring gear orientation to carrier. Remove ring gear bolts (typically 10-12 bolts in a crisscross pattern). If bolts are tight, apply heat to carrier near bolt holes. Tap ring gear off carrier using soft mallet. Drive out differential pin and remove spider gears, side gears, and thrust washers. Label all components.
   ⚠Ring gear bolts may have thread locker. Heat may be required for removal.
6. 6

   Remove carrier bearings
   Using a bearing puller or press, remove both side bearings from carrier. Mark bearings left and right if reusing. Inspect carrier for cracks, wear, or damage. Clean carrier thoroughly and inspect all surfaces.
   ℹ️Side bearings typically require replacement during rebuild. Inspect races in housing for pitting or wear.
7. 7

   Remove pinion gear assembly
   Mark pinion flange orientation and count rotational torque required to turn pinion (record for reference). Remove pinion nut while holding flange. Use puller to remove companion flange. Tap pinion out from front of housing. Catch pinion, crush sleeve, inner bearing, and any shims as assembly comes out.
   ⚠Pinion nut is very tight. Use proper size socket to avoid rounding. Removing pinion nut destroys crush sleeve which must be replaced.
8. 8

   Remove pinion bearings and races
   Press or drive inner pinion bearing off pinion shaft. Remove pinion seal from housing using seal puller. Drive out front and rear pinion bearing races from housing using brass drift. Remove any shims behind rear bearing race and measure/record thickness. Inspect pinion gear teeth for wear, pitting, or damage.
   ℹ️Pinion depth shim thickness is critical for proper gear mesh. Record original shim thickness for reference.
9. 9

   Clean and inspect all components
   Thoroughly clean differential housing, all gears, and components with solvent. Inspect ring and pinion teeth for scoring, pitting, or abnormal wear patterns. Check housing for cracks. Inspect bearing races in housing for wear. Replace ring and pinion as a matched set if any damage is found. Inspect spider and side gears for wear.
   ⚠Ring and pinion gears must always be replaced as a matched set. Never mix gears from different sets.
10. 10

    Install new pinion bearings and set depth
    Press new rear pinion bearing onto pinion shaft. Install pinion depth shim(s) in housing based on markings on new gear set or original shim thickness. Press rear bearing race into housing. Install pinion with rear bearing into housing without seal or front bearing. Install front bearing race. Press front bearing onto pinion. Install companion flange temporarily without seal to check pinion depth.
    ℹ️Pinion depth is set by shims behind rear bearing race. New gear sets include depth variance markings that must be followed.
11. 11

    Set pinion bearing preload
    Install new crush sleeve on pinion shaft. Install front pinion bearing, pinion seal (lightly oiled), and companion flange. Install new pinion nut with thread locker. Tighten pinion nut gradually while checking rotational preload with inch-pound torque wrench. Target preload is typically 16-29 inch-pounds for new bearings. Once achieved, do not back off nut as crush sleeve cannot be reused.
    ⚠️Pinion nut must not be backed off once tightened or crush sleeve is damaged. If preload is exceeded, crush sleeve must be replaced and process restarted.
    ⚠Tighten pinion nut in small increments and check preload frequently to avoid overshooting specification.
12. 12

    Install ring gear on carrier
    Heat ring gear to approximately 200°F to expand for easier installation. Align marks made during disassembly and install ring gear on carrier. Install new ring gear bolts with thread locker. Tighten bolts in crisscross pattern to specification (typically 100-120 ft-lbs, check service manual). Allow to cool completely.
    ⚠Do not overheat ring gear. Excessive heat can damage heat treatment. Use temperature indicating crayon or infrared thermometer.
13. 13

    Assemble carrier internals
    Install side gears and thrust washers into carrier. Install spider gears and thrust washers, ensuring proper mesh. Install differential pin and secure with lock bolt and thread locker. Check that gears rotate smoothly without binding. Press new side bearings onto carrier using appropriate driver.
    ℹ️Ensure thrust washers are correct thickness and properly positioned to prevent gear binding.
14. 14

    Install carrier and set backlash
    Install carrier bearing races if not already installed. Install carrier into housing with initial shim pack. Install bearing caps in original orientation per alignment marks. Snug cap bolts. Mount dial indicator to housing with probe on ring gear tooth. Check ring gear backlash at multiple points. Target is typically 0.005-0.009 inches. Adjust by moving shims from one side to other (maintaining total preload).
    ⚠Backlash must be checked at 4-6 positions around ring gear. Variation should not exceed 0.003 inches indicating bent carrier or runout.
15. 15

    Check gear contact pattern
    Apply gear marking compound to several ring gear teeth. Rotate pinion through several revolutions in both directions while applying resistance. Remove carrier and inspect contact pattern on ring gear teeth. Pattern should be centered on tooth face. Adjust pinion depth shims if pattern is too high or low on tooth. Adjust backlash if pattern is too far toward toe or heel.
    ℹ️Proper gear contact pattern is critical for quiet operation and gear life. This may require multiple iterations of shim adjustment.
16. 16

    Final assembly of carrier
    Once backlash and contact pattern are correct, torque bearing cap bolts to specification (typically 75-85 ft-lbs, verify in service manual). Verify backlash has not changed after final torque. Check carrier bearing preload by measuring rotational torque (should increase 5-10 inch-pounds over pinion preload). Install new axle seals in housing using seal driver.
    ℹ️Total rotating torque should be pinion preload plus carrier preload. Excessive preload causes bearing failure.
17. 17

    Install differential cover and fill
    Clean cover and housing mating surfaces thoroughly. Apply continuous bead of RTV sealant to cover (or install new gasket per manufacturer specifications). Install cover and bolts. Torque cover bolts in crisscross pattern to specification. Allow RTV to cure per product instructions (typically 1 hour). Install and torque fill plug. Fill differential with 75W-90 GL-5 gear oil to bottom of fill hole (approximately 1.5 quarts). Install and torque drain plug with new washer.
    ⚠Allow RTV to cure before filling with oil. Verify correct fluid specification for front differential.
    Torque spec

    Cover Bolts42 Nm (31 lb-ft)

    Fill Plug51 Nm (38 lb-ft)

    Drain Plug51 Nm (38 lb-ft)
18. 18

    Install driveshaft and CV axles
    Install front driveshaft to companion flange aligning marks made during disassembly. Install U-joint strap bolts and torque evenly to specification. Install CV axles into differential flanges and torque CV bolts to specification. Insert axle shafts into wheel hubs. Install and torque axle nuts to specification. Install new cotter pins through axle nuts.
    ℹ️Ensure CV axle splines are clean and lightly greased before installation. Align driveshaft marks to maintain balance.
    Torque spec

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

    CV Bolts76 Nm (56 lb-ft)

    Axle Nut250 Nm (184 lb-ft)

Reassembly

1. Install wheels and torque lug nuts to specification in star pattern
2. Lower vehicle to ground
3. Reconnect negative battery cable
4. Test drive vehicle and listen for abnormal noises from differential
5. Recheck fluid level after test drive and top off if necessary

Verification

• Check for fluid leaks around differential cover, pinion seal, and axle seals
• Listen for whining, howling, or grinding noises during test drive at various speeds
• Verify smooth operation during acceleration and deceleration
• Check for vibration that could indicate driveshaft misalignment
• Recheck differential fluid level after 100 miles and inspect for metal particles
• Verify proper 4WD engagement if equipped with selectable 4WD

More procedures for this vehicle