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I did it on my 01 X and now I did it on my 06 F250...
The diff cover was looking pretty rough, so I knew it was time to change the fluid and give a fresh coat of paint.
Notice how 'frothy' the old fluid looked... not to pretty IMHO. But the gears looked good...
Got the cover sanded as best I could - I wish I had access to a sand blaster. If it survives another 100K, I'll just replace it next time.
The plug looked good - not too much magnetized to it.
I got all cleaned up, applied 2 coats of Hi Temp Paint and laid a bead of red RVT around it then replaced the cover. After letting it sit over night I refilled with Royal Purple 75w/140 the next morning.
I got a little messy with the Red RVT and will clean it up better later on...
I gotta do mine soon. How many quarts does it take and is there a gasket on there.
Thanks,
Steve
IIRC it takes 4 qts and there is NO gasket. Use the Ford or Permatex gray sealer.
The cast aluminum rear diff. cover from an 08 is really a great addition to do when you change the fluid. It's fairly cheap but does require a little longer bolt.