Two-Piece, Traction-LOK
Special Tools:
Disassembly
1. Remove the differential case.
2. Remove the ring gear bolts.
3. NOTE: The anti-lock speed sensor ring cannot be reused once removed.
Insert a punch in the bolt holes and drive the ring gear off.
^ If necessary, remove the anti-lock speed sensor ring and discard it.
4. If the differential bearings require removal.
5. NOTE: This tool does not have the 1/2-inch drive hole.
Position the Traction-Lok Torque Tool Set in a vise.
6. Position the differential case on the Traction-Lok Torque Tool Set.
7. Index mark the differential case halves.
8. Remove the differential case bolts.
9. Remove the right differential case half and differential side gear.
10. Remove the differential pinion shaft and differential pinion gears.
11. Remove the differential pinion gears from the differential pinion shaft.
12. Remove both differential side gears and differential clutch packs from each differential case half
13. Remove the Belleville spring and shim(s) from both differential clutch packs.
Assembly
1. Prelubricate each clutch disc and soak the clutch friction plate for at least 15 minutes in Additive Friction Modifier C8AZ- 19B5 46-A or equivalent meeting Ford specification EST-M2C118-A.
2. CAUTION: Do not mix the differential clutch packs or shims from one side with the other.
NOTE: The Belleville spring is a dished plate.
Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.
3. NOTE: Use the Traction-Lok Clutch Gauge Mandrel for the procedure.
Clamp the bolt head of the Traction-Lok Clutch Gauge in a vise.
^ Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.
4. Position the Traction-Lok Clutch Gauge disc on top of the differential clutch pack.
5. Install the Traction-Lok Clutch Gauge housing over the disc and tighten the nut.
6. Use a feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack.
^ The reading will be the thickness of the new clutch shim.
^ Select the correct shim size, and remove the Traction-Lok Clutch Gauge.
7. Place the selected shim and Belleville spring on the differential clutch pack.
^ The dished or concave side of the Belleville spring must be face up and against the thrust face of the differential case.
8. Install the differential side gear and differential clutch pack into the left case half (ring gear side).
9. Position left differential case half on the Traction-Lok Torque Tool Set.
10. Lubricate the differential pinion gears, pinion gear thrust washers and the differential pinion shaft with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
^ Install the differential pinion gears in the differential pinion shaft.
11. Install the differential pinion shaft and the differential pinion gears.
12. Install the right differential clutch pack and differential side gear into the right case half
13. Position the right differential case half with the index marks aligned.
14. Install the retaining bolts and tighten.
15. Check the torque required to rotate one differential side gear.
^ Install the Traction-Lok Torque Tool Set with the 1/2-inch drive hole as shown.
^ The initial break-away torque, if the original clutch plates are used, must be within specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.
16. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts.
17. Install the differential case.