Rear Differential Cover removal

[01Expo.XLT]

I have a 2001 Expedition 4 x4 w/5.4. with 120,000 miles and although the manual says it is "lifetime" I am planning on changing the rear differential fluid. I looked under the vehicle and I see there is a bar across the back of the rear end close to the top portion of the differential cover.

My questions are:

Is there enough clearance to remove the differential cover without removing this bar or anything else?

How many quarts of Motorcraft 75w140 synthetic fluid is required and how many bottles of friction modifier are required? The Axle code is H9 (3.55 limited slip)

To those of you who have done this, is a gasket recommended?

Thank You

 

[stamp11127]

You need to move it out of the way to get the cover off. Additive is usually 4oz. and rear dope quantity hasn't been measured since I've pumped out of a 5 gal pail when doing these. Check with a dealer to make sure.

 

[01Expo.XLT]

That is what I thought. Thank You

 

[Bedrck47]

SECTION 205-02A: Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 2001 Expedition/Navigator Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 06/24/2000


Differential Housing Cover
Removal

WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

Raise and support the vehicle. For additional information, refer to Section 204-04 .
NOTE: Empty the lubricant into a clean container for reuse.

Remove the differential housing cover (4033).
Remove the 10 bolts and drain the lubricant from the differential housing (4010).
Remove the differential housing cover.

Installation

CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.

Clean the differential housing cover and differential housing gasket mating surface.
CAUTION: Install the differential housing cover within 15 minutes of applying the silicone material.

Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
Use Clear Silicone Rubber F7AZ-19554-CA or equivalent meeting Ford specification ESB-M4G92-A.

CAUTION: Allow the sealant to cure for one hour before filling the axle with lubricant.

Install the differential housing cover.
Position the differential housing cover.
Install the 10 bolts.

CAUTION: For Traction-Lok® axles, first fill the rear axle with 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.

NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant 6.4-14.3 mm (0.25-0.57 in) below the bottom of the filler hole.

Fill the rear axle with 2.5-2.6 liters (5.25-5.50 pints) of SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A and install the filler plug.

NOTE: If equipped with air suspension, reactivate the system.

Lower the vehicle.

--------------------------------------------------------------------------------------------------

SECTION 205-02B: Rear Drive Axle/Differential — Ford 9.75-Inch Ring Gear 2001 Expedition/Navigator Workshop Manual
IN-VEHICLE REPAIR Procedure revision date: 02/13/2003


Differential Housing Cover
Removal

WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

Raise and support the vehicle.
Position the rear stabilizer bar and rear axle tracking bar aside.
NOTE: Empty the lubricant into a clean container for reuse.

Remove the differential housing cover (4033).
Remove the 12 differential housing cover bolts and drain the lubricant from the rear axle housing (4010).
Remove the differential housing cover.

Installation

CAUTION: Make sure the machined surfaces on both the rear axle housing (4010) and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the rear axle (4001) must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the rear axle and the differential housing cover.
Apply a new, continuous bead of sealant to the differential housing cover.
Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A.

NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured.

Install the differential housing cover and tighten the differential housing cover bolts.

NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the specified level below the bottom of the filler hole.

Fill the rear axle with specified lubricant, and install the filler plug.
For Traction-Lok® axles, first fill the rear axle with 118 ml (4 ounces) of specified Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.

Position and secure the rear stabilizer bar and rear tracking bar.
Lower the vehicle.

 

[Bedrck47]

Rear axle fluid1 Motorcraft SAE
75W140
Synthetic Rear
Axle Lubricant
All
2.9-3.1L
(5.5-5.8 pints)
1 Your vehicle’s rear axle is
equipped with synthetic rear axle
lubricant. Rear axles containing
synthetic lubricant are lubricated
for life. These lubricants are not to
be checked or changed unless a
leak is suspected, service required
or the axle has been submerged in
water. The axle lubricant should be
changed any time the axle has
been submerged in water. Add 118
ml (4 oz.) of additive friction
modifier C8AZ-19B546–A, Ford
specification EST-M2C118–A
whenever the fluid is changed.
Service refill capacities are
determined by filling the rear axle
6 mm to 14 mm (1/4 inch to 9/16
inch) below the bottom of the filler
hole.

 

[01Expo.XLT]

Thank You roxy1225 for the info. You've answered all of my questions.