This procedure covers the complete removal and replacement of the rear differential assembly on a 2015-2020 Ford F-150 with 5.0L V8 and RWD configuration, including driveshaft disconnection, axle removal, and differential reinstallation.

Warnings

Tools required

Parts

• Differential cover gasket × 1 — Use OEM specification
• Driveshaft U-joint strap bolts (if reusing) × 4 — Use OEM specification
• RTV silicone sealant (if gasket not used) × 1 — Motorcraft TA-31
• Shop rags × 1 — Generic

Fluids

• Motorcraft 75W-140 Synthetic Gear Oil — 2.5 qt

Preparation

1. Park vehicle on a level surface and engage parking brake
2. Chock the front wheels securely
3. Raise rear of vehicle and support on jack stands at frame rails, ensuring sufficient clearance to lower differential
4. Remove both rear wheels and tires
5. Place drain pan beneath differential
6. Allow vehicle to cool if recently driven to avoid hot gear oil burns

Procedure

1. 1

   Drain differential fluid
   Remove the differential cover bolts in a crisscross pattern, starting with the top bolts. Leave two bolts at the top partially threaded to control fluid drainage. Once fluid slows, remove remaining bolts and carefully pry cover off using a pry bar. Clean the mating surface on the differential housing with a wire brush and remove all old gasket material.
   Torque spec

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

   Mark driveshaft orientation
   Using marking paint or chalk, mark the driveshaft yoke and differential pinion flange alignment. This ensures proper balance during reassembly. Mark both sides of the joint so the relationship is clear.
3. 3

   Disconnect driveshaft from differential
   Remove the four driveshaft U-joint strap bolts or flange bolts connecting the rear driveshaft to the differential pinion flange. Support the driveshaft and carefully lower it away from the differential. Secure the driveshaft to the exhaust or frame with wire to prevent it from hanging on the center bearing.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
4. 4

   Remove rear brake calipers and rotors
   Remove the rear brake caliper mounting bolts and hang calipers from the frame using wire or zip ties - do not let them hang by the brake hoses. Remove the rear brake rotors to access the axle nuts. This provides clearance for axle shaft removal.
5. 5

   Remove axle shaft retaining hardware
   On this F-150 configuration, the rear axles are retained by the differential itself. Remove the differential cover (already done in step 1) to access the C-clip retainers inside the differential. Rotate the axles and remove the pinion shaft lock bolt, then slide out the pinion shaft. Push the axle shafts inward and remove the C-clips from the button end of each axle shaft.
   ⚠Keep track of the small C-clips as they can easily fall and be lost. Place them in a container immediately after removal.
6. 6

   Remove axle shafts
   Carefully pull both rear axle shafts outward from the differential housing. You may need to rotate them slightly to clear the differential gears. Once free, remove them completely from the axle tubes and set aside in a clean area to prevent damage to the bearing surfaces.
7. 7

   Disconnect parking brake cables
   Release the parking brake cable retaining clips at the differential housing or axle tube brackets. Disconnect both left and right parking brake cables from their mounting points to allow differential removal.
8. 8

   Disconnect ABS sensor connectors and vent tube
   Disconnect both rear ABS wheel speed sensor electrical connectors if they route near the differential. Remove the differential vent tube from the top of the differential housing - it typically pushes into a rubber grommet.
9. 9

   Support differential with transmission jack
   Position a transmission jack with differential adapter under the center of the differential housing. Raise the jack until it just contacts the differential and supports its weight. Ensure the differential is stable and balanced on the jack before proceeding.
   ⚠️The differential will become unstable once mounting bolts are removed. Ensure the transmission jack is properly centered and secured before removing any mounting hardware.
10. 10

    Remove differential mounting bolts
    Locate and remove all differential-to-frame mounting bolts. On the F-150, these are typically located at the nose of the differential (front mount) and at the rear spring perches or frame brackets. There are usually 4-6 mounting bolts total. Keep track of any shims or spacers at the mounting points.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
11. 11

    Lower and remove differential
    Carefully lower the transmission jack, guiding the differential assembly down and away from the vehicle. You may need to angle it slightly to clear the frame rails and suspension components. Once clear, roll the differential out from under the vehicle. Handle with care due to its weight.
12. 12

    Install replacement or serviced differential
    Position the replacement or rebuilt differential on the transmission jack and roll it under the vehicle. Carefully raise it into position, aligning the mounting points with the frame brackets. You may need an assistant to guide the differential and align the mounting holes. Install all mounting bolts finger-tight initially.
    Torque spec

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

    Reconnect components and install axle shafts
    Reconnect the differential vent tube and ABS sensor connectors. Reconnect parking brake cables to their brackets. Carefully slide both axle shafts into the differential housing through the axle tubes, rotating as needed to engage the differential side gears. Push the axle shafts inward, install the C-clips on the button ends, then pull the shafts outward to seat the C-clips. Install the pinion shaft and secure with its lock bolt.
14. 14

    Reconnect driveshaft
    Raise the driveshaft to the differential pinion flange, aligning the marks made during disassembly. Install the U-joint strap bolts or flange bolts and tighten evenly in a crisscross pattern to prevent binding.
    Torque spec

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

    Install differential cover and fill with gear oil
    Install a new gasket or apply a 1/8 inch bead of RTV silicone sealant to the differential cover mating surface. Install the cover and tighten bolts in a crisscross pattern to ensure even seating. If using RTV, wait 15-30 minutes before filling. Fill the differential with 2.0-2.5 quarts of Motorcraft 75W-140 synthetic gear oil through the fill hole until oil reaches the bottom of the fill plug opening. Install and tighten the fill plug.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
16. 16

    Reinstall brake components and wheels
    Reinstall the rear brake rotors and brake calipers. Torque caliper mounting bolts to specification. Reinstall both rear wheels and hand-tighten lug nuts in a star pattern. Lower the vehicle to the ground and torque lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and secured with their locking tabs
2. Verify parking brake cables are properly routed and secured to prevent interference with suspension travel
3. Double-check that all mounting bolts are torqued to specification
4. If RTV sealant was used on differential cover, allow at least 1 hour cure time before driving

Verification

• With vehicle on level ground, check differential fluid level at the fill plug - oil should be at the bottom of the fill hole
• Test parking brake operation to ensure cables are properly connected and adjusted
• Start vehicle and verify no ABS warning lights are illuminated on the dashboard
• Test drive the vehicle at low speed in a safe area, listening for unusual noises from the differential
• After test drive, recheck differential cover for any signs of leakage
• Check for any driveshaft vibration - if present, recheck alignment marks and U-joint strap torque
• Inspect under vehicle for any fluid leaks after 50-100 miles of driving

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