Ok... lets ask this a different way...

[DP96XLT]

Ok, I will keep it simple here.

Can the front diff cover be removed without pulling the entire diff?

I have no problem unbolting it and the driveshaft if I can somehow swing the assembly back for more clearance. Or is clearance not and issue to unbolt it? Side-note: I do have a full compliment of tools including ratcheting combination wrenches.

I also have no problem using a steel-cored, rubber encased and silicon beaded cover gasket instead of silicone, thus I don't have to worry about smearing RTV anywhere. The only issue I see is being able to clean up the case well enough for when I put the cover gasket and new cover on.

Any input on this is appreciated...

I figured my previous post was too detailed, thus why I got no replies.

 

[C420sailor]

I don’t think so. I wouldn’t want to work like that, anyway.

I use a suction gun to change front fluid. When the seals start getting iffy, or if she needs more than just fluid, out she comes.

Not sure if a cover exists that has an accessible drain plug?

 

[DP96XLT]

I need to remove the cover to replace it with the "impossible to find" cover with a baffle and vent that fixes the fluid being pushed out the vent tube on the stock design.

 

[DP96XLT]

Also, I also use a vacuum device to suck out all the stock fluid on fluid changes. Just in this case I have been pushing the fluid out the front original stock vent tube... I guess driving at 75-80mph on the expressway with 75w90 Mobil 1 synthetic in the diff is a bad combination.

 

[C420sailor]

Are you sure your diff isn’t eating itself? I’ve been running 80W90 in my front diff for 327,000mi and it’s still original, no puking out the tube.

Is the tube routed correctly? How hot is the pumpkin getting after a long drive?

 

[Mbrooks420]

I agree with above. If you’re puking oil, it’s either getting hot, or it’s overfilled.

 

[DP96XLT]

No, it is not eating itself, gears are fine, bearings are fine, no leaks.

It is obviously coming out the vent tube that is routed to the vacuum reservoir "bulb" on the passenger side of the engine bay. No doubts about where it is coming from, it is from the vent.

Ford issues a TSB around 2002-2003 or so where they outlined the issue and listed a "fix" which is a new diff cover with a baffled vent location. You plug the original vent location on the housing and use the new vent on the cover. I already acquired the last cover available anywhere.

The service bulletin: TSB 05-6-20

The cover kit: F6TZ-4033-BA

And, actually the TSB covers the entire repair, and you CAN just drop the diff down while leaving everything else connected and change the cover out that way. They call for new bushing bolts and nuts. Other than that it looks like a cakewalk.

Here is the link to the TSB: https://testing-public.carmd.com/Tsb/Download/35048/tsb05-06-20

 

[DP96XLT]

And in regards to being overfilled, it is not. It is the required distance below the fill plug when I filled it. It was a full 3/5 of a quart low when I pulled the fill plug to check the level. I already refilled it.

Also, no idea why some people have the problem and others don't. Personally I drive this vehicle at 75-80mph for 20-40 miles at a time. Speed limit is 70mph where I am at and I rarely go more than 8-9 mph over the speed limit. I figure most people don't drive theirs that fast and that is why others aren't seeing the issue.

Oh, and the vent is routed all upwards, so no dips that can collect fluid. After I noticed the vent belching fluid out one day I fixed any sort of dips.

 

[C420sailor]

Ohhhh you’ve got an early model with the vacuum disconnect. I’m not smart on that diff.

 

[410Fortune]

Just drop the diff it only takes a few minutes

 

[DP96XLT]

Just drop the diff it only takes a few minutes

Yeah, that is what they outline in the TSB. You just undo the nuts to the bushing bolts and unbolt the one bushing bracket. Then you put a jack underneath, jack it up and then pull the bolts out of the remaining two bushings. Then you drop it down as the axles rest on the torsion bars and you can get at the entire front cover area without restriction.