This procedure drains and replaces the rear differential fluid on a 2015-2020 Ford F-150 with the 5.0L V8 Coyote engine, ensuring proper lubrication and longevity of the rear axle components.

Warnings

Tools required

Parts

• Rear differential cover gasket × 1 — Motorcraft RG-5416 or equivalent
• Differential fill plug O-ring (if applicable) × 1 — Use OEM specification

Fluids

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

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Raise rear of vehicle using floor jack at appropriate rear axle lift points
4. Support vehicle on jack stands placed under frame rails behind rear axle
5. Allow differential to cool if vehicle was recently driven

Procedure

1. 1

   Locate and clean differential cover
   Position yourself under the rear of the vehicle and locate the rear differential cover (large oval or rectangular cover on the rear of the differential housing). Clean the area around the cover bolts and drain area with brake cleaner and a rag to prevent contamination.
2. 2

   Position drain pan
   Place a drain pan with at least 3-quart capacity directly under the differential cover. Position it slightly toward the bottom of the cover where fluid will drain most heavily.
3. 3

   Loosen differential cover bolts
   Using a 13mm socket, loosen all differential cover bolts but do not remove them completely. Start with the top bolts and work your way around, leaving the bottom bolts for last. This allows you to control the fluid release.
4. 4

   Drain differential fluid
   Carefully remove the bottom cover bolts first, then slowly pry the cover away from the housing at the bottom edge to allow fluid to drain. Once fluid flow slows, remove the remaining bolts and carefully remove the cover. Be prepared for additional fluid to drain. Allow all fluid to drain completely (approximately 5-10 minutes).
   ⚠Fluid will drain quickly once cover is loosened. Keep hands and drain pan positioned to catch fluid.
5. 5

   Clean differential cover and housing surface
   Remove all old gasket material from both the differential housing mating surface and the cover using a gasket scraper or plastic scraper. Be careful not to gouge the aluminum housing. Clean both surfaces thoroughly with brake cleaner and wipe with a clean rag until no debris remains. Inspect the drained fluid and housing interior for metal shavings or debris that could indicate wear.
6. 6

   Install new gasket and position cover
   Place the new differential cover gasket onto the cover or housing (depending on gasket design). Align the gasket with all bolt holes. Carefully position the differential cover onto the housing, ensuring the gasket stays in place and all bolt holes align.
7. 7

   Install and torque cover bolts
   Install all differential cover bolts by hand, threading them in evenly. Once all bolts are hand-tight, torque them in a criss-cross pattern to 35 Nm (26 lb-ft) to ensure even gasket compression and prevent leaks.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
8. 8

   Locate and access fill plug
   Locate the differential fill plug on the front of the differential housing (typically on the driver side or center). Clean the area around the fill plug. Remove the fill plug using the appropriate socket or wrench. Inspect the O-ring on the fill plug and replace if worn or damaged.
9. 9

   Fill differential with new fluid
   Using a fluid pump or funnel with hose, add approximately 2.0 quarts of Motorcraft 75W-140 Synthetic Gear Oil through the fill hole. Fill until fluid begins to seep out of the fill hole, indicating proper level. If your differential is equipped with limited-slip, add the appropriate limited-slip additive per manufacturer specification before topping off.
   ℹ️Proper fill level is reached when fluid just begins to drip from the fill hole. Do not overfill.
10. 10

    Reinstall fill plug
    Install the fill plug with new O-ring (if applicable) and tighten by hand until seated, then snug with wrench. Do not overtighten as the plug typically does not have a high torque specification. Wipe away any spilled fluid from the differential housing.
11. 11

    Lower vehicle and verify
    Carefully lower the vehicle from the jack stands and remove stands. Lower the vehicle completely to the ground. Inspect the differential cover and fill plug for any signs of leakage. Wipe the area clean for easier leak detection during the test drive.

Reassembly

1. Ensure all differential cover bolts are torqued to specification in a criss-cross pattern
2. Verify fill plug is properly seated and not cross-threaded
3. Clean any spilled fluid from differential housing and surrounding components

Verification

• Start engine and allow to idle briefly, then check for leaks around differential cover and fill plug
• Take a short test drive (5-10 minutes) including some turns to distribute fluid throughout the differential
• Re-inspect differential cover and fill plug for any signs of leakage after test drive
• Check fluid level by briefly removing fill plug - fluid should be at the bottom of the fill hole threads

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