Disassembly

Differential Case:

Special Tools:

NOTE: The differential bearings need not be removed to overhaul the Ford Limited-Slip Differential. Removal and installation of the side gears, clutch packs, pinion gears and thrust washers require special procedures and tools as described below.

Carrier:

1. Remove the differential pinion shaft lock bolt.

Differential Holding Tool:

2. Install differential assembly Holding Tool, D83T-4205-A, in a suitable vise. Install differential assembly in the vise with the ring gear side facing up.

Pinion Shaft Removal:

3. With a hammer and drift, drive the pinion shaft from the differential case.

Side Gear Removal:

4. Install Step Plate, D83T-4205-C2, in bottom side gear bore. Apply a small amount of grease to centering hole of the step plate.

Side Gear Removal:

5. Install nut in upper side gear. Hold nut in position while installing Hex Screw Tool (part of D83T-42O5-C).

6. Insert Dowel Bar or equivalent, part of D83T-42O5-C, in hole of nut. Tighten forcing screw to force side gears away from the pinion mating gears. The dowel bar is used to keep the nut from turning when the forcing screw is tightened.

Side Gear Removal:

Pinion Gear Removal:

7. With an appropriate size feeler gauge, push the pinion gear thrust washers out from between the pinion gears and the differential case. Remove the thrust washers, then back off the forcing screw until it is loose (approximately one turn).

Pinion Gear Removal:

8. Insert Rotating Tool T86T-4205-A in the pinion shaft bore and turn the case to "walk" the pinion gears out to the differential case windows. Remove the pinions.

NOTE: Make sure vise is tightened securely during this Step.

9. Remove the forcing screw and step plates. Remove the side gears, retainer clips and clutch pack assemblies.

Clutch Pack Removal:

Differential Case:

10. Remove the retainer clips from both clutch packs to allow separation of the discs and plates for cleaning and inspection.

CAUTION: When separating the clutch plates and discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence.