Tools You'll Need:
* Jack and Jack Stands: Essential for safely lifting the truck. Never work under a vehicle supported only by a jack.
* Wheel Chocks: To secure the front wheels.
* Socket Set and Wrench Set (metric): Various sizes will be needed.
* Torque Wrench: Crucial for tightening bolts to the correct specification. Incorrect torque can damage the differential.
* Drain Pan: To catch the differential fluid.
* New Differential Cover Gasket: A crucial part to prevent leaks.
* New Differential Fluid: The correct type and amount is specified in your owner's manual.
* Funnel: For pouring the new fluid.
* Gloves: To protect your hands from the old fluid.
* Cleaning Rags or Shop Towels: To clean up any spills.
* Pry Bar (optional): May be helpful to gently break the old gasket free.
* Impact Wrench (optional): Can speed up the process, but be careful not to over-tighten.
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, and chock the front wheels. Wear safety glasses.
2. Raise and Secure: Safely lift the rear of the truck using the jack and securely position it on jack stands.
3. Remove the Wheels: Remove the wheels on the axle you're working on.
4. Drain the Differential Fluid: Locate the drain plug on the bottom of the differential housing. Place the drain pan underneath and carefully remove the plug. Allow the fluid to drain completely. Note the fluid's condition – this can give you clues about potential problems.
5. Remove the Differential Cover: Locate the bolts holding the differential cover in place. Use the appropriate socket and carefully remove each bolt. The cover may be stuck on due to the gasket. Gently pry around the edges with a pry bar (if needed) to break the seal. Once loose, carefully remove the cover.
6. Clean the Surfaces: Thoroughly clean the mating surfaces of the differential housing and the old cover. Remove all traces of the old gasket material. Use a gasket scraper if necessary.
7. Install the New Gasket: Carefully apply the new differential cover gasket according to the manufacturer's instructions. Ensure it is properly seated.
8. Install the New Cover: Align the new cover and carefully bolt it back onto the differential housing. Do not over-tighten. Tighten the bolts in a star pattern (opposite bolts in sequence) to ensure even pressure.
9. Torque the Bolts: Use the torque wrench to tighten the bolts to the manufacturer's specified torque. This is critical to prevent leaks and damage. Consult your owner's manual or a repair manual for the correct torque specification.
10. Refill with Differential Fluid: Consult your owner's manual to determine the correct type and amount of differential fluid for your axle. Use a funnel to carefully pour the new fluid into the differential. Check the fluid level using the fill plug; it should be close to the bottom of the fill hole.
11. Install Fill Plug: Replace the fill plug, tightening it to the manufacturer's specifications.
12. Lower the Truck: Carefully lower the truck from the jack stands.
13. Replace the Wheels: Reinstall the wheels and tighten the lug nuts to the proper torque.
14. Check for Leaks: Inspect the differential for any leaks. Start the engine and let it run for a few minutes to check for leaks while observing the differential.
15. Dispose of Used Fluid Properly: Take the used differential fluid to a recycling center or auto parts store that accepts used oil.
Important Considerations:
* Axle Type: Knowing your specific axle type (e.g., Sterling 10.5, Dana 50) will help you find the correct parts and torque specifications.
* Torque Specifications: Incorrect torque can damage your differential. Always consult your repair manual.
* Fluid Type: Use the correct type of differential fluid as recommended by Ford for your truck.
This is a general guide. If you are not comfortable performing this repair, it is best to take your truck to a qualified mechanic. Improperly performing this repair can lead to damage to your differential and other components.
