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How To Remove & Install F-150 Lightning 9.75" Rear Differential Cover | 99-04

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How To Remove & Install F-150 Lightning 9.75" Rear Differential Cover | 99-04 - How To Remove & Install F-150 Lightning 9.75" Rear Differential Cover | 99-04

What You Will Need:

Decent socket set

Drain pan or bucket

Lube locker gasket or RTV silicone to reseal the cover to the rear end

Quality brake clean

Towels

Gasket scraper

Medium duty scuff pads

Please note before you change the rear end gear oil and is always best to check the owner’s manual for the recommended oil weight and that the fill plug can be removed.

Removal

Safely support the truck via A-lift or jack stands.

Locate the fill plug on the side of the rear end housing. Clean it off first if there is any heavy debris.

Verify that this plug can be removed. This is removed by a 3/8” drive extension.

Once this is done you can thread back in with a couple of turns.

Place a drain pan or bucket underneath the rear end housing and loosen and remove all of the bolts except for the top one.

With the top bolt you just need to loosen a few turns.

Gently pry open the cover to separate the silicone or gasket material and allow the old oil to drain.

Loosen and remove the top bolt and set the cover aside.

Use a towel or something clean to remove the old oil from the bottom of the rear end housing.

Use this opportunity to visually inspect all of the components in the rear end.

Before cleaning the mating surface on the rear end housing cover the entire assembly with a microfiber towel.

Use the gasket scraper and scrape away the old gasket material or silicone. Scuff the surface with a scuff pad to get nice and smooth.

Flush out the bolt holes with brake clean and compressed air to dislodge old silicone and foreign material.

Thoroughly wipe the mating surface with a clean towel and brake clean.

If you are going to be reinstalling the factory differential cover, clean it with the same process as you did the rear end housing.

Remove the microfiber towel and give the differential one last look.

Installation

In this video we install a lube locker gasket and an aftermarket cover from Ford Performance.

If you are only reinstalling the factory cover, apply a 1/8” of RTV silicone to the rear end or cover. Make sure you go underneath the bolt hole or simply apply a bead all the way around the hole.

Align the cover with the rear end, and get the top bolt started.

Loosely install the rest of the bolts, then you can run them all down by hand.

There isn’t a specified torque sequence for these bolts, but because of the design, it is best to torque in a cross pattern. If you are reinstalling a factory cover and hardware, torque the bolts to 33 lb-ft. If installing an aftermarket cover with different hardware, use the torque specs recommended by the manufacturer of the cover.

Allow the RTV silicone to cure per the manufacturer’s recommendations, before filling the housing with fluid.

If you have installed an aftermarket cover, verify the drain plug is fully tightened.

Go ahead and open the fill plug and fill the rear end housing with the recommended amount of gear oil or until the fluid begins to seep out of the hole.

If you aren’t using an aftermarket cover with a fill hole, fill the differential with fluid through the factory fill hole.

If you’re filling the rear end through the aftermarket cover, apply a high temp thread sealer with PTFE to the factory fill plug.

Reinstall the factory fill plug and torque to 22 lb-ft.

Remember, if your vehicle is equipped with a traction lock rear end you must add 4oz of friction modifier if the fluid you are using doesn’t have it pre-mixed.

Wipe up any fluid from the housing, reinstall the plug, and torque to 22 lb-ft.

Give everything a once-over and you’re good to go!

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About the Video

How To Remove & Install Lightning 9.75" Rear Differential Cover (99-04)

Check out our YouTube channel for even more tech tips, installation videos, how-tos, and more. The best place to go for anything Mustang related!

Published on 2020-04-24
Buy Ford Performance 9.75" Rear Differential Cover: https://latemodelres.to/M4033F975_Removal
Buy 9.75" Rear End Service Kit: https://latemodelres.to/F975-K
Buy LubeLocker 9.75" Rear Differential Cover Gasket: https://latemodelres.to/F975

Follow along as Landan walks you through the steps of removing and installing your 9.75" rear differential cover, while refilling with new fluid, on your 99-04 Ford Lightning.

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How To Remove & Install F-150 Lightning 9.75" Rear Differential Cover | 99-04

Removal

Installation

1999-2004 SVT Lightning 9.75" Rear End Parts

About the Video

How To Remove & Install Lightning 9.75" Rear Differential Cover (99-04)

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