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

Last Updated 5/6/2020 by Taylor Ward

FOLLOW: ford lightning , 99 04 lightning , how to , rear end , ford performance

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


  1. Safely support the truck via A-lift or jack stands.
  2. 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


  3. Locate the fill plug on the side of the rear end housing. Clean it off first if there is any heavy debris.
  4. 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


  5. Verify that this plug can be removed. This is removed by a 3/8” drive extension.
  6. 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


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



  8. Place a drain pan or bucket underneath the rear end housing and loosen and remove all of the bolts except for the top one.
  9. 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


  10. With the top bolt you just need to loosen a few turns.
  11. 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


  12. Gently pry open the cover to separate the silicone or gasket material and allow the old oil to drain.
  13. 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


  14. Loosen and remove the top bolt and set the cover aside.
  15. 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


  16. Use a towel or something clean to remove the old oil from the bottom of the rear end housing.
  17. 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


  18. Use this opportunity to visually inspect all of the components in the rear end.
  19. 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


  20. Before cleaning the mating surface on the rear end housing cover the entire assembly with a microfiber towel.
  21. 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


  22. 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.
  23. 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


  24. Flush out the bolt holes with brake clean and compressed air to dislodge old silicone and foreign material.
  25. 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

    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


  26. Thoroughly wipe the mating surface with a clean towel and brake clean.
  27. 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


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



  29. Remove the microfiber towel and give the differential one last look.
  30. 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


Installation


  1. In this video we install a lube locker gasket and an aftermarket cover from Ford Performance.
  2. 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


  3. 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.



  4. Align the cover with the rear end, and get the top bolt started.
  5. 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


  6. Loosely install the rest of the bolts, then you can run them all down by hand.
  7. 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


  8. 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.
  9. 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


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



  11. If you have installed an aftermarket cover, verify the drain plug is fully tightened.
  12. 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


  13. 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.
  14. 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


  15. If you aren’t using an aftermarket cover with a fill hole, fill the differential with fluid through the factory fill hole.
  16. 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


  17. If you’re filling the rear end through the aftermarket cover, apply a high temp thread sealer with PTFE to the factory fill plug.
  18. 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


  19. Reinstall the factory fill plug and torque to 22 lb-ft.
  20. 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


  21. 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.
  22. 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


  23. Wipe up any fluid from the housing, reinstall the plug, and torque to 22 lb-ft.
  24. 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


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

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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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
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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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