Complete removal and replacement of the rear differential assembly on a 2011-2014 Ford F-150 4WD with 5.0L V8 Coyote engine, including driveshaft disconnection, axle shaft removal, and differential mounting.

Warnings

Tools required

Parts

• Rear differential assembly (if replacing complete unit) × 1 — Use OEM specification
• Differential cover gasket × 1 — Use OEM specification
• RTV silicone sealant (if gasket not used) × 1 — Motorcraft TA-31 or equivalent
• Cotter pins for axle nuts × 2 — Use OEM specification
• Crush washer for fill plug × 1 — Use OEM specification

Fluids

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

Preparation

1. Park vehicle on level ground and apply parking brake firmly
2. Chock front wheels securely on both sides
3. Loosen rear wheel lug nuts while vehicle is still on ground
4. Raise rear of vehicle and support securely on jack stands under frame rails behind rear axle
5. Remove both rear wheels completely
6. Position drain pan under rear differential

Procedure

1. 1

   Drain differential fluid
   Remove the differential cover bolts in a cross pattern, starting from the top. Leave two bolts at the top partially threaded to control fluid release. Carefully pry cover loose at bottom to allow fluid to drain into pan. Once drained, remove remaining bolts and cover. Clean mounting surface thoroughly with wire brush and scraper.
   Torque spec

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

   Mark and remove driveshaft
   Use a paint marker or scribe to mark the relationship between the driveshaft yoke and differential pinion flange for proper alignment during reassembly. Remove the four U-joint strap bolts at the rear differential. Support the driveshaft and carefully slide it rearward to separate from pinion yoke. Wire the driveshaft up and out of the way to the exhaust or frame.
   ⚠Do not allow driveshaft to hang unsupported as this can damage the center support bearing or front U-joint.
   Torque spec

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

   Remove rear brake components and ABS sensors
   Remove rear brake calipers and secure to frame with wire (do not let hang by brake hoses). Remove brake rotors. Disconnect ABS wheel speed sensor connectors on both sides and carefully unclip wiring from axle tubes. Remove parking brake cables from backing plates if equipped with rear drum-in-hat parking brake.
   ⚠Do not depress brake pedal with calipers removed or brake pistons may extend beyond recovery.
4. 4

   Remove axle shaft retention hardware
   Remove and discard the cotter pins from both axle shaft nuts. Use a breaker bar and appropriate socket to loosen and remove both rear axle nuts. These are torqued to 250 Nm and will require significant force. Keep axle nuts if reusing, but replace cotter pins with new ones during reassembly.
   ℹ️Have an assistant apply brakes or use a pry bar against wheel studs to prevent axle rotation while loosening nuts.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
5. 5

   Disconnect CV axle shafts from differential
   On each side, locate the six CV bolts connecting the inner CV joint to the differential side flange. Remove all six bolts per side. Carefully pull the axle shafts outward and secure them to the frame or suspension with wire to prevent damage to CV boots. Do not allow axles to hang freely.
   Torque spec

   CV Bolts76 Nm (56 lb-ft)
6. 6

   Disconnect differential vent hose and sensors
   Locate the differential vent hose on top of the housing and disconnect it. Disconnect the rear differential temperature sensor connector if equipped. Disconnect any wiring harness clips attached to the differential housing. Carefully route wiring away from the differential.
   ℹ️Take photos of wiring routing before disconnection to aid in proper reinstallation.
7. 7

   Support differential with transmission jack
   Position a transmission jack or suitable differential jack under the center of the differential housing. Raise jack until it just contacts the housing and takes slight weight off the mounting bolts. Secure differential to jack with a strap or chain to prevent it from falling when bolts are removed.
   ⚠️Ensure jack is centered and stable before removing mounting bolts. Differential will shift when bolts are removed.
8. 8

   Remove differential mounting bolts
   Locate the differential mounting bolts connecting the housing to the leaf spring perches or mounting brackets. Typically there are four main mounting bolts. Support the differential weight with the jack and remove all mounting bolts. Have an assistant help stabilize the differential as the final bolt is removed.
   ⚠️Differential weighs 100-120 lbs and will shift when final mounting bolt is removed. Ensure jack is secure and have assistant ready.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
9. 9

   Lower and remove differential assembly
   Slowly and carefully lower the transmission jack while guiding the differential assembly down and away from the vehicle. Watch for any remaining connections or interference with suspension components, brake lines, or exhaust. Once clear of the frame, roll the differential assembly out from under the vehicle.
   ⚠Rear leaf springs may shift position slightly when differential is removed. Ensure they remain properly seated on frame perches.
10. 10

    Prepare replacement differential
    If installing a used or remanufactured differential, verify correct gear ratio matches your vehicle specification (check door jamb sticker). Ensure all mounting surfaces are clean. Install new cover gasket or apply RTV silicone sealant in a continuous bead. Install cover and torque cover bolts. Fill differential with 2.0 quarts of Motorcraft 75W-140 synthetic gear oil through fill hole until it reaches the bottom of the fill plug hole.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
11. 11

    Install differential assembly into vehicle
    Position the replacement differential on the transmission jack and secure with strap. Carefully raise and maneuver the assembly into position under the vehicle, aligning mounting points with leaf spring perches or brackets. Have an assistant guide from above while you operate the jack. Align all mounting holes before installing bolts.
    ⚠Take care not to damage brake lines, ABS wiring, or vent hose during installation.
12. 12

    Install mounting bolts and torque
    Install all differential mounting bolts finger-tight first to ensure proper alignment. Then torque all mounting bolts to specification in a cross pattern. Verify differential is sitting flush against all mounting surfaces before final torquing. Remove transmission jack once all bolts are torqued.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
13. 13

    Reconnect CV axles and install hardware
    Guide each axle shaft inner CV joint to align with the differential side flange. Install all six CV bolts per side and torque to specification in a star pattern. Install axle nuts on both sides and torque to 250 Nm. Install new cotter pins through axle nut castellations and bend properly to secure.
    ℹ️Ensure CV joint splines are fully engaged before tightening bolts. Axle should not pull away from differential when torqued.
    Torque spec

    CV Bolts76 Nm (56 lb-ft)

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

    Reinstall driveshaft
    Align the marks made during disassembly on the driveshaft yoke and differential pinion flange. Position U-joint into yoke and install U-joint strap bolts. Torque bolts evenly in a cross pattern to prevent binding. Verify driveshaft rotates freely by hand after installation.
    ⚠Misalignment of driveshaft marks can cause vibration. Verify marks are properly aligned before tightening.
    Torque spec

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

    Reconnect sensors and install brake components
    Reconnect differential vent hose, temperature sensor connector, and ABS wheel speed sensors on both sides. Secure all wiring clips to axle tubes. Reinstall parking brake cables if removed. Install brake rotors, then reinstall brake calipers. Install wheels and hand-tighten lug nuts.
    ℹ️Pump brake pedal several times after caliper installation to reseat brake pads before lowering vehicle.
16. 16

    Lower vehicle and final torque
    Carefully lower vehicle to ground. Torque wheel lug nuts to specification in a star pattern. Start engine and verify no unusual noises from differential. Check for any fluid leaks around differential cover and pinion seal.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Always use new cotter pins for axle nuts - never reuse old pins
2. Verify driveshaft alignment marks match before final tightening to prevent vibration
3. Double-check that all ABS sensors are properly connected and secured
4. Ensure differential vent hose is routed away from heat sources and moving components

Verification

• Test drive vehicle at low speed and verify smooth operation with no vibration or abnormal noises from rear differential
• Check for fluid leaks around differential cover, pinion seal, and axle seals after test drive
• Verify proper brake operation and ABS function with no warning lights
• After 50-100 miles, recheck differential fluid level and top off if necessary
• Listen for proper gear engagement during acceleration and deceleration

More procedures for this vehicle