2003 Expedition Rear Differential Cover, 4X4

[s julius]

Hi folks,
I have a 2003 Expedition 4X4 with H6 rear axle code. My axle is two half-shafts with control arms at each wheel. I've never played with this axle before, and the seal at the cover is leaking and pulling it to reseal has me stumped. Looks like I have to pull two bolts that go through the diff (or maybe outside of it) to pull the cover, and it looks really tight to re-install. Anyone have any advice? I've searched and haven't found what I need; procedure, how many bolts and how to reach them, is a true gasket available, etc. Thanks very much for any info.

 

[kevinb]

I need to replace the diff cover gasket on my 04. Any chance you've done the work on yours yet, and if so, would you share any info on how bad it was to do?

 

[s julius]

Haven't done it yet, but this is what I've learned. I think:
You'll need to remove the brakes, rotors, knuckles -so that you can pull the CV shafts. I have pulled one of my shafts, couldn't find the 'special tool' for rental at my local autoparts places, so I used a wonder bar (hooked end) and rotated the shaft as I smacked the prybar with a 4-lb drillers hammer. Once you've removed the shafts, you remove the two nuts that keep the diff attached to the frame member (from behind the diff, recessed in the two holes at 3 and 9 oclock), then remove the nut at the front of the brace in front of the diff. Remove that corresponding forward bolt, drop the rear sway bar out of the way, and pull the diff forward to remove. Maybe others repair the seal/rtv/gasket with the diff in place on a lift, but I don't have much confidence in my ability to do that on my back beneath it on jacks stands in my driveway, because it looks to me like you'd have to pull the cover rearward to clear the two bolts, and there's not room enough with that frame member. There's some tsb's, I'll look for them and post the numbers.

FYI if you start this; I did replace the bearing and seal for the shaft I removed, and was glad I did it. I used timkens for like $10 apiece from amazon, as the rollers in my bearing were completely frozen.