This procedure drains and refills the front differential fluid on a 4WD 2015-2020 Ford F-150 with the 5.0L V8 Coyote engine, ensuring proper lubrication of the front axle assembly.

Warnings

Tools required

Parts

• Differential cover gasket × 1 — Motorcraft YF-1964 or equivalent RTV silicone gasket maker
• Crush washer for fill plug (if applicable) × 1 — Check existing plug condition

Fluids

• Motorcraft 75W-140 Synthetic Gear Oil — 1.5 qt

Preparation

1. Verify vehicle is 4WD equipped by confirming presence of front driveshaft
2. If vehicle was recently driven, allow front differential to cool for at least 30 minutes
3. Park vehicle on level surface and engage parking brake
4. Place wheel chocks behind rear wheels
5. Raise front of vehicle and support securely on jack stands at frame rail contact points
6. Remove front skid plate if equipped (retain hardware for reinstallation)

Procedure

1. 1

   Locate the front differential
   The front differential is positioned between the front wheels, forward of the transmission. Identify the differential cover (oval-shaped pan on the rear face) and locate both the fill plug (upper position on cover or housing) and drain plug or cover bolts (lower position).
2. 2

   Clean the differential cover area
   Use a wire brush to clean around the differential cover bolts and fill plug area, removing dirt and debris. This prevents contamination from entering the differential during service.
3. 3

   Remove the fill plug first
   Using a 10mm socket or appropriate tool, loosen and remove the fill plug from the differential housing. This ensures you can refill the differential after draining. If the fill plug is seized or damaged, do not proceed with draining until the fill plug issue is resolved.
   ⚠Always remove the fill plug before draining. If the fill plug cannot be removed, you will not be able to refill the differential after draining.
4. 4

   Drain the differential fluid
   Position drain pan directly beneath the differential cover. Remove all differential cover bolts using a 10mm socket, loosening them in a criss-cross pattern. Start at the top and work downward, leaving 2-3 bottom bolts slightly snug. Carefully remove the remaining bolts and pry the cover away gently, allowing fluid to drain into the pan. Remove the cover completely once drainage slows.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
5. 5

   Clean the differential cover and housing
   Scrape all old gasket material from both the differential cover and the housing mating surface using a plastic scraper. Do not gouge or damage the machined aluminum surfaces. Wipe both surfaces clean with shop rags. Inspect the drained fluid for metal shavings or debris; minor fine particles are normal, but large chunks or excessive metal indicate potential component wear.
6. 6

   Prepare and install new gasket
   If using a pre-cut gasket, position it on the differential cover ensuring all bolt holes align. If using RTV silicone, apply a continuous 3mm bead around the inside edge of the bolt holes on the cover, and around the perimeter. Do not allow RTV to extend into the differential cavity where it could contaminate the gears.
7. 7

   Reinstall the differential cover
   Carefully position the cover with gasket onto the differential housing, aligning all bolt holes. Install all cover bolts hand-tight first. Using a torque wrench and 10mm socket, torque the bolts in a criss-cross pattern starting from the center and working outward to ensure even gasket compression and prevent leaks.
   Torque spec

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

   Refill the front differential
   Using a fluid transfer pump or squeeze bottle with extension hose, insert the nozzle into the fill plug hole. Add Motorcraft 75W-140 Synthetic Gear Oil slowly until fluid begins to drip from the fill hole. The correct fill level is reached when fluid is level with the bottom of the fill plug hole (approximately 1.5 quarts). Allow fluid to settle for 1-2 minutes and top off if needed.
   ℹ️Use only Motorcraft 75W-140 Synthetic Gear Oil or equivalent meeting Ford specification WSP-M2C192-A. Do not substitute with other viscosities.
9. 9

   Install the fill plug
   Wipe the fill plug threads clean and inspect the sealing washer. Replace the crush washer if equipped. Thread the fill plug into the housing by hand, then tighten snugly with a socket. Do not overtighten as the housing is aluminum and threads can strip.
10. 10

    Inspect for leaks and reinstall skid plate
    Wipe the differential cover area completely dry with a clean rag. If skid plate was removed, reinstall it with original hardware. Lower the vehicle from jack stands and remove wheel chocks.

Reassembly

1. Ensure all differential cover bolts are torqued to specification in a criss-cross pattern
2. Verify fill plug is installed and snug
3. Reinstall front skid plate if it was removed
4. Double-check that no tools or rags are left under the vehicle

Verification

• Start the engine and shift the transfer case through all positions (2H, 4H, 4L if equipped) while stationary
• Drive the vehicle forward and backward a short distance to circulate fluid through the front differential
• Re-check the area around the differential cover and fill plug for any signs of leakage
• After 50-100 miles of driving, perform a visual inspection underneath the vehicle to confirm no leaks have developed
• Proper fluid level is confirmed if gear oil is level with the bottom of the fill plug hole when removed on level ground

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