How to service and repair the Dana S135 differential carrier on 2001 Ford F-250 Super Duty?

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Safety must be established before servicing the Dana S135 differential carrier because exposing components to heat can result in damage. Dirt prevention will be achieved through steam cleaning of the axle assembly. Use the parking brake and wheel chocks while draining axle lubricant from the drain plug followed by its clean installation. Disconnect the rear anti-lock brake sensor electrical connector while also indexing and removing the driveshaft and loosening the pinion hex nut according to requirements. Pry action must avoid the axle shaft flange and should not separate the hub from the flange to prevent any harm. Use a marker to note down the correct orientation of the axle shaft flange before removing all axle shafts. Keep only the longest two housing retaining bolts for the carrier-to-axle connection while taking down measurements of their lengths along with retaining bolt positions. Begin by securing the carrier with a jack and proceed to remove the carrier from the axle housing through use of a jack positioned beneath the carrier followed by removal of remaining bolts until the carrier separates from the housing. Clean the components either with emulsion cleaners or petroleum-based solvents followed by lintless towel drying before using rust inhibitor or clean lubricant to stop corrosion. Check for damage in the gear set while inspecting spline wear along with the examination of the axle flange O-ring. Check for damage inside the axle housing while performing a cleaning operation. Check the differential case and ring gear instructions when requiring disassembly of components. Installation starts by applying a continuous bead of Ford Gasket Maker F8AZ-19B508-AB on the axle housing mounting flange followed by inserting two alignment studs into the housing before positioning the carrier into its space without allowing any obstruction to the bolt threads. First apply Thread lock 262 E2FZ-19554-B to the bolts and then install them before you remove the alignment studs a few bolts at a time. You need to install the axle shafts while reconnecting the driveshaft and rear anti-lock brake sensor and removing the fill plug before adding Motorcraft SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL until it reaches the fill hole's surface. Reinstall the fill plug after cleaning it then remove wheel chocks followed by releasing the parking brake.

OEM 2001 Ford F-250 Super Duty Differential

7 Differentials found

2001 Ford F-250 Super Duty Differential Assembly Part Number: F81Z-4026-A

2001 Ford F-250 Super Duty Differential Case Part Number: F75Z-4204-BA

2001 Ford F-250 Super Duty Differential Case Part Number: LC3Z-4205-A

2001 Ford F-250 Super Duty Differential Case Part Number: F6TZ-4204-AA

2001 Ford F-250 Super Duty Differential Case, Front Part Number: D7TZ-4204-C

2001 Ford F-250 Super Duty Case, Front Part Number: F81Z-3204-BA

2001 Ford F-250 Super Duty Ring & Pinion, Front Part Number: E3TZ-3204-D

2001 Ford F-250 Super Duty Differential

2001 Ford F-250 Super Duty Differential Parts Q&A

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