This procedure covers removal and installation of the rear differential assembly on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including driveshaft disconnection, axle removal, and fluid service.

Warnings

Tools required

Parts

• Differential cover gasket × 1 — Use OEM specification
• Differential fill plug gasket × 1 — Use OEM specification
• RTV silicone gasket maker (if gasket not used) × 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. Chock front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle and support securely on jack stands at frame contact points
5. Remove both rear wheels
6. Place drain pan under differential

Procedure

1. 1

   Drain differential fluid
   Remove the differential cover bolts in a crisscross pattern to allow fluid to drain gradually. Once fluid begins draining, remove remaining bolts and carefully remove cover. Allow all fluid to drain completely into drain pan. Inspect drained fluid for metal shavings or debris that could indicate internal wear.
   Torque spec

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

   Mark and disconnect rear driveshaft
   Use a paint marker or scribe to mark the relationship between the driveshaft and the differential pinion yoke for proper alignment during reassembly. Remove the four U-joint strap bolts at the differential end. Support the driveshaft and carefully slide it rearward off the pinion yoke. Secure the driveshaft out of the way or remove completely if necessary. Do not allow the driveshaft to hang unsupported as this can damage the center bearing.
   ℹ️Mark driveshaft orientation before removal to prevent driveline vibration issues during reassembly.
   Torque spec

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

   Disconnect rear brake lines and ABS sensors
   Disconnect the brake line mounting brackets from the differential housing. Unplug the rear ABS wheel speed sensor connectors on both sides. Disconnect the rear brake hose junction point if it connects directly to the differential housing. This prevents damage when lowering the differential.
   ⚠Do not allow brake lines to stretch or kink. Support them with wire or zip ties if necessary.
4. 4

   Remove axle shafts from differential
   If equipped with independent rear suspension (IRS), remove the CV bolts connecting the inner CV joints to the differential flanges on both sides. If equipped with solid rear axle, the axle shafts will remain with the differential housing during removal. For IRS models, support the halfshafts and secure them out of the way with wire or bungee cords to prevent damage to CV boots.
   Torque spec

   CV Bolts70 Nm (52 lb-ft)
5. 5

   Support differential with transmission jack
   Position a transmission jack or suitable differential jack under the center of the differential housing. Raise the jack until it just contacts the differential and securely chain or strap the differential to the jack. The differential must be stable on the jack before removing mounting bolts.
   ⚠️Differential weighs 90-110 lbs and contains heavy internal components. Ensure jack is properly positioned and secured before removing mounting bolts.
6. 6

   Disconnect vent hose and wiring
   Locate and disconnect the differential vent hose from the top of the housing. Unplug any remaining electrical connectors for the differential temperature sensor or other sensors if equipped. Label all connectors for proper reassembly.
7. 7

   Remove differential mounting bolts
   Remove all differential mounting bolts that secure the housing to the rear subframe or axle mounts. There are typically 4-6 mounting points depending on configuration. Have an assistant support the differential or ensure the transmission jack is securely supporting the weight. Remove bolts gradually and evenly to prevent binding.
   ⚠Verify transmission jack is stable and differential is secured before removing final mounting bolts.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Lower and remove differential assembly
   Carefully lower the transmission jack while guiding the differential assembly clear of the vehicle. Watch for any remaining hoses, wires, or components that may still be attached. Once clear of the vehicle, move the differential to a clean workbench for inspection or service. If only servicing (fluid change, seal replacement), this full removal may not be necessary.
9. 9

   Clean and inspect mounting surfaces
   With the differential removed, clean all mounting surfaces on the vehicle frame and subframe. Inspect rubber mounting bushings for wear, cracking, or deterioration. Inspect the differential housing for cracks, stripped threads, or damage. Clean the differential cover mating surface with a gasket scraper and wire brush, removing all old gasket material and RTV. Inspect internal gears and bearings for wear if accessible.
10. 10

    Install differential cover with new gasket
    Place new differential cover gasket on housing, or apply a continuous 3-4mm bead of RTV silicone gasket maker to the cover mating surface if gasket is not used. Position the differential cover and install all cover bolts finger tight. Tighten bolts in a crisscross pattern to the specified torque to ensure even gasket compression and prevent leaks.
    ℹ️If using RTV silicone, allow 15-30 minutes cure time before filling with fluid per manufacturer instructions.
    Torque spec

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

    Reinstall differential assembly
    Position the differential on the transmission jack and carefully raise it into position, aligning mounting holes with the frame or subframe brackets. Install all mounting bolts finger tight first, then torque to specification in a crisscross pattern. Reconnect the differential vent hose and all electrical connectors.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
12. 12

    Reconnect axle shafts and driveshaft
    For IRS models, align the inner CV joint flanges with the differential output flanges and install CV bolts, torquing to specification. Reconnect the rear driveshaft to the pinion yoke, aligning the marks made during disassembly. Install new U-joint strap bolts and tighten evenly to specified torque to prevent imbalance.
    Torque spec

    CV Bolts70 Nm (52 lb-ft)

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)
13. 13

    Reconnect brake lines and ABS sensors
    Reattach all brake line mounting brackets to the differential housing. Reconnect rear ABS wheel speed sensor connectors. Reconnect brake hose junction points. Ensure no lines are pinched, kinked, or under tension.
14. 14

    Fill differential with gear oil
    Locate the differential fill plug on the side of the housing. Remove the fill plug and inspect/replace the gasket. Using a gear oil pump or fluid transfer pump, add Motorcraft 75W-140 Synthetic Gear Oil until it begins to drip from the fill hole. The differential should hold approximately 2.0 quarts. Install fill plug with new gasket and tighten securely.
    ℹ️Fill until fluid is level with the bottom of the fill plug hole. Overfilling can cause seal leaks and overheating.
15. 15

    Install wheels and lower vehicle
    Install both rear wheels and hand-tighten lug nuts in a star pattern. Lower the vehicle until wheels just contact the ground. Torque all lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Verify all mounting bolts are torqued to specification
2. Ensure driveshaft alignment marks are properly matched to prevent vibration
3. Check that all brake lines and ABS sensors are properly secured and connected
4. Verify differential is filled to proper level with correct fluid
5. Double-check all electrical connectors are fully seated

Verification

• Start vehicle and verify no warning lights on dashboard (ABS, traction control, etc.)
• Test drive vehicle at low speed and verify smooth operation with no unusual noises from differential
• After test drive, inspect differential cover and all connections for leaks
• Verify proper brake operation during test drive
• After 50-100 miles, re-check differential fluid level and inspect for leaks
• Re-torque differential cover bolts after initial drive if recommended by gasket manufacturer

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