I'm just trying to think once I get a new cover how the hell am I supposed to fill it up again, I can either drill a hole and use a plug as shown in the previous picture or I can try the ABS sensor hole...I tried pulling the sensor earlier but it seemed like it was in there pretty well.

 

how can they not get the plug off? all you need is a 1/2" drive rachet. i think its 1/2" anyway

 

just paint it and get rid of the truck ASAP.

 

I guess it could be somewhat stripped, but still; I'm not sure how it could be stripped bad enough to where an impact wouldn't back it out. I mean, it's four sides and deep, how could it be totally stripped?

Iduno, probably just corroded, maybe they couldn't get enough *** behind it lol. Seems like they could have put the heat to it if necessary, specially once apart. Yea, not sure, never had that problem and my 98 has rusted bad enough so that I have to clean out the 1/2" slot in order for the extension to fit lol.

Would be a PITA to drill out. Well, a right angle die grinder and carbide burr bit would make quick work of it..BUT, then there's the shavings dilemma. Actually, the shavings could easily be handle by plugging the port with greasy rag from the inside.

Crap, -I bet I'd have that plug out in 8 seconds, -bring it over.

 

No, you Do Not use a gasket for these. Ford doesn't, I've never seen one used on these F150's, so I wouldn't recommend it. I know that they have them. Not sure how long they'll work. Go ahead and use one if you must. It might be easier for yuh. Personally, I'd rather follow procedure from design and engineering = Ford Service. After all, they built this thing. What do they know, right...

From Service:

 

I didnt use a gasket on mine. Permatex makes a tube of black stuff that works great.. Extra large just for dif covers.

 

I'm guessing that you don't have a grinder to smooth it out? Personally, that would have been an expectation of mine that if they weld it and glob it up like that, they clean up and grind it smooth.

 

Take a look at Tasca or Silverstate ford. My cover wouldn't seal when I had my gears changed. I ended up buying one from Silverstate, it was like 12 dollars.

 

Well seeing as they know a whole lot better than I do I'm not going to use a gasket now lol, I never was really to "mechanically inclined" if you want to call it that until I bought this truck, so im learning things day by day as things keep continually breaking on me lol.

Where can you pick that up at? Autozone?

Nope I do not have a grinder, although I think my neighbor does and I may just borrow it and see how it goes, worth a shot, if it still looks messed up i'll just slap a new cover on , trial and error.

 

I always fill with the wheel speed sensor just because its a bigger hole

 

Damn! That's good to know. I didn't realize that could be done.

So all you would have to do, - Drain it, wipe out the bottom (little sump there) and refill w/spec quantity. Might have to measure that out before hand. Lots easier than getting that certain amount out of the last bottle, and at that angle lol.

Sounds good, as long as you break off nothing on that sensor. That could suck lol.

 

Yes, even some parts stores don't even carry the gasket. Just use the RTV, I used the blue and it worked fine. just be sure to get all the oil out of the bottom cavity or it will keep dripping preventing a good seal adherence with rtv.
BTW I probably just would've got a used cover at a local salvage yard.
That fill plug must be in there really tight, maybe heat it up and try removal again.

 

I just did mine with a gasket from Advanced Auto.
Drain into a clean pan after cleaning the outside so it can be reused if desired.
The fill plug is a 3/8" square indent headed plug.
The fluid is normally in a squize bottle and fills through the fill hole without a problem.
Get 2 bottles and fill until it begins to run out , then put the plug in.
Total time was less then 30 minutes to do the whole job.
Reason I did it was had the cover off and the liquid seal didn't seal completely so to be sure on the second effort, used a gasket.
.
BTW, for the op, the ring gear bolts normally are loc-tighted in so they don't come out.
Some one made a mistake and did not use any at assembly time.
There may be others that might come out sometime if this is the case.
Good luck.