aFe Power 46-70080 User manual

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Instruction Manual P/N: 46-70080 / 46-70082
Dana 60 –10 Bolt Front Differential Cover
Make: Ford Model: F250/F350 Year: 99-16 Engine: V8 –7.3L/6.0L/6.4L/6.7L (td)
Make: Ford Model: F250/F350 Year: 11-16 Engine: V8 –6.2L
Make: Ford Model: Excursion Year: 00-05 Engine: V8 –7.3L/6.0L (td)

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• Please read the entire instruction manual before proceeding.
• Ensure all components listed are present.
• If you are missing any of the components, call customer support at 951-493-7100.
• Ensure you have all necessary tools before proceeding.
• Ensure that your vehicle is cooled off before proceeding.
• Retain factory parts for future use.
Label
Qty.
Description
Part Number
A1
1
Differential Cover –Raw, Machined Fins
(46-70080)
05-60975A
A2
1
Differential Cover –Black, Machined Fins
(46-70082)
05-60976B
B
1
RTV Silicone
05-60096
C
10
Screw, Socket Head 3/8”-16x1”
03-50229
D
10
Washer, Flat
03-50230
E
1
Washer, Crush M12
03-50384
F
2
Plug, 1/8” NPT
03-50029
G
1
Plug, 3/4” NPT
(Included in 46-70080)
03-50391
H
1
Plug, Magnetic 3/4” NPT, 6” Deep Reach
(Included in 46-70082)
03-50223
I
1
Plug, 1” NPT Sight Glass
(Included in 46-70082)
03-50224
J
1
Plug, Magnetic M12x1.25
03-50385

2
A1
A2
B
C
D
E
J
G
H
I
F

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1. Park your vehicle on a flat, dry surface. You will need to block the tires to prevent the
vehicle from rolling.
2. Place a drain pan under the differential cover.
3. Remove the bottom nine (9) bolts from the differential cover, leaving only the top bolt.
4. Loosen, but do not remove, the top bolt. Break the seal on the cover and the gear oil will
begin to drain.

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5. Allow all of the gear oil to drain from the differential.
6. If your vehicle has a breather port attached directly to the differential cover, remove it
now.
7. Remove the one (1) remaining bolt from the top of the differential cover.
8. Carefully insert a gasket scraper between the differential cover and the housing. Pry the
differential cover off. Do not gouge the sealing surface.
9. Remove the OEM cover from the housing.

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10. Use a clean, lint free shop towel to wipe down the remaining gear oil from the housing.
11. Clean off the sealing surface with a gasket scraper. Be careful not to gouge the surface
while cleaning.
12. Check the surface of the housing for any irregularities. If there are any, carefully remove
high spots using a smooth flat file.
Note: Do not “Round Off” the flat gasket surface.

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13. Hold the supplied aFe differential cover up to the gasket surface to make sure you will be
able to maneuver it into place easily.
Note: If applicable, you can re-use the OEM gasket in place of silicone.
14. Spread the supplied RTV silicone across the gasket surface. Be generous when spreading
the silicone across the surface, ensuring to follow along the inside of all the bolt holes.
Note: Before moving on, make sure that the silicone will completely seal with the gasket
surface.

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15. Hold the aFe differential cover into position, aligning the screw holes. Install four (4) of the
supplied 3/8”-16x1”socket head screws and flat washers into separate sides of the cover
to hold it in place.
Note: Be careful not to move the cover around once it touches the gasket surface.
16. Continue installing the remaining 3/8”-16x1”socket head screws and flat washers finger
tight.
17. Torque the mounting screws to 12-16 ft. -lbs. in a crisscross pattern.

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18. Install the supplied M12x1.25 drain plug and crush washer into the bottom of the cover.
When installing kit number 46-70082 only:
19. Apply Teflon pipe sealant to the threads and install the supplied 1” NPT Sight Glass plug
into the side of the cover.

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20. Using the top fill port, fill the aFe differential cover using new gear oil. Fill until gear oil runs
out of the 1/8” NPT port on the side of the cover (about 4 quarts).
Note: If your vehicle is lifted and your axle has been rotated, you will have to verify you have
the correct oil level for your vehicle.