SECTION 205-02: Rear Drive Axle/Differential
2014 Flex Workshop Manual
IN-VEHICLE REPAIR
Procedure revision date: 05/02/2013

Differential Housing Cover


Material
Item Specification
Clear Silicone Rubber
TA-32 		ESB-M4G92-A
Motorcraft® SAE 80W-90 Premium Rear Axle Lubricant
XY-80W90-QL (US); CXY-80W90-1L (Canada) 		WSP-M2C197-A


Item Part Number Description
1 W505262 Differential housing cover bolt (10 required)
2 4N282 Filler plug

Removal

NOTICE: The differential housing cover is only serviceable on vehicles equipped with a stamped steel differential housing cover. Vehicles equipped with a aluminum differential housing cover replace the complete Rear Drive Unit (RDU) assembly.

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .
  1. If equipped, remove the exhaust insulator located near the differential housing cover using soapy water.

  1. NOTE: Drain the differential fluid into a suitable drain pan.

    Remove the 10 bolts and the rear differential housing cover.

Installation

  1. NOTE: Make sure the machined surfaces on the rear axle housing and the differential housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.

    Clean the gasket mating surfaces of the differential housing and the differential housing cover.

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

    Apply a new continuous bead of clear silicone rubber as shown in the illustration.
  1. Install the differential housing cover and the 10 bolts.
  1. Remove the filler plug and fill the rear axle with 1.15L (2.43 pt) of rear axle lubricant, 3-5 mm (0.118-0.196 in) below the bottom of the filler hole.
  1. If equipped, install the exhaust insulator located near the differential housing cover.