Differential Case and Ring Gear-Traction-Lok
Special Tools:
Disassembly
1. Remove the differential case.
2. Remove the 10 ring gear bolts.
3. CAUTION: Care should be taken not to damage the ring bolt hole threads.
Insert a punch in the bolt holes and drive the ring gear off.
4. Note: The anti-lock speed sensor ring cannot be reused once removed.
Remove the speed sensor ring if required.
5. Using the special tools, remove the differential bearing.
- Repeat for the other side.
6. Remove and discard the differential pinion shaft lock bolt and remove the differential pinion shaft.
7. WARNING: Due to the spring tension, care must be used when removing the differential clutch spring.
Remove the differential clutch spring.
8. Remove the differential gears.
1 Remove the two differential pinion gears.
2 Remove the two differential side gears.
3 Remove the two differential pinion thrust washers.
9. CAUTION: Keep the differential clutch packs in order. Do not mix them. They must be reassembled in the same sequence.
Remove the differential clutch packs and differential side gears and tag them " right" and "left" with the shim.
- Clean and inspect the remaining parts of the differential case for wear or damage and install new parts as necessary.
10. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only.
Clean and inspect the differential clutch packs for wear and install new parts as necessary.
Assembly
1. CAUTION: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the axle.
Note: Differential Clutch Pack Rebuild Kit F5ZZ-4947-BA is available for rebuild of the 7.5-inch ring gear, Traction-Lok.
Prelubricate each steel clutch plate and soak all friction plates with additive Ford Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.
2. CAUTION: Do not mix the differential clutch packs or shims from one side with the other.
Assemble the differential clutch packs (without the shims) on the respective differential side gears.
3. CAUTION: Make sure the correct mandrel is used with the special tool.
Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge.
4. Position the special tool hand-tight on top of the differential clutch pack.
5. Install the special tool over the disc and clutch pack.
6. Install the nut of the special tool over the top and base stud.
7. Use a suitable 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.
Selective Shims
Part Number Description
E4DZ-4A324-G 0.025 Inch
E4DZ-4A324-H 0.030 Inch
E4DZ-4A324-C 0.035 Inch
E4DZ-4A324-D 0.040 Inch
E4DZ-4A324-F 0.045 Inch
8. Remove the special tool from the clutch pack and side gear assembly.
9. Install shims on the clutch pack and side gear assembly.
10. Install the differential side gears in the differential case.
11. Install the differential pinion gears with differential pinion thrust washers in the differential case.
12. Install the differential clutch spring, using a soft-faced hammer.
13. Note: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation.
Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.
14. Check the torque required to rotate one differential side gear.
- Mount the differential case and special tool in a vise
- The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.
15. Using the special tool, install the differential bearing on the differential case. Repeat for the other side.
16. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
Press the new anti-lock speed sensor ring and the ring gear on the differential case.
17. Install the ring gear bolts.
- Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts.
18. Install the differential case.