Ford F150 Pickup. Manual - part 604

Fig. 35: Removing Pinion Seal 
Courtesy of FORD MOTOR CO. 

Installation 

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 9.75-inch - F150 Pickup

  

1. Lubricate the new rear axle drive pinion seal. 

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Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 

Fig. 36: Installing Rear Axle Drive Pinion Seal 
Courtesy of FORD MOTOR CO. 

2. Using the special tool, install the rear axle drive pinion seal.  

3. Install the pinion flange. For additional information, refer to DRIVE PINION FLANGE .  

DIFFERENTIAL HOUSING COVER 

Removal 

1. Raise and support the vehicle. 

CAUTION: If the rear axle drive pinion seal becomes misaligned during 

installation, remove the seal and install new.

NOTE:

Empty the lubricant into a clean container for reuse.

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 9.75-inch - F150 Pickup

  

Fig. 37: Removing Differential Housing Cover 
Courtesy of FORD MOTOR CO. 

2. Remove the differential housing cover (4033). 

1. Remove the 12 differential housing cover bolts, and drain the lubricant from the rear axle housing 

(4010).  

2. Remove the differential housing cover.  

Installation 

1.

Clean the gasket mating surface of the rear axle and the differential housing cover. 

2. Apply a new, continuous bead of sealant to the differential housing cover. 

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Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A 
and ESE-M4G195-A. 

CAUTION: Make sure the machined surfaces on both the rear axle housing 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.

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 9.75-inch - F150 Pickup

  

Fig. 38: Applying Silicone Sealant 
Courtesy of FORD MOTOR CO. 

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.

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 9.75-inch - F150 Pickup