Differential Case and Ring Gear
Differential Case and Ring Gear
Special Tool(s)
Disassembly
1. Mount the carrier housing in a suitable repair stand.
2. CAUTION: If reusing the differential ring gear and pinion measure and record the backlash before disassembly. Re-assembling the differential ring gear and pinion to the recorded backlash will match the established wear patterns. Hand rolled patterns will cover less area than the established patterns.
Measure and record the differential ring gear and pinion backlash.
- Check the backlash in four equally spaced positions around the differential ring gear.
The acceptable backlash tolerance is + 0.0508 mm (0.002 inch) from the backlash etched in the differential ring gear.
- The tooth contact pattern can move only by adjusting backlash. The tooth contact pattern can move only in the direction of heel-to-toe, and toe-to-heel. Depth of the tooth contact pattern is not adjustable. Contact Spicer Service at 1-800-666-8688 for assistance if you are unable to establish an acceptable tooth contact pattern within the limits of backlash.
3. Remove the rear anti-lock brake sensor.
4. Remove the adjusting ring locks (4143).
5. Loosen, but do not remove, the four bolts.
6. Relieve the bearing preload.
- Loosen each differential bearing adjusting ring.
7. NOTE: The differential bearing caps are match marked at the factory.
Remove the bolts, bearing caps and adjusting rings.
8. CAUTION: Do not damage the differential ring gear and pinion.
Using the special tool, carefully lift the differential subassembly out of the carrier.
9. Using the special tool, and a suitable puller, remove the differential side bearings if worn/damaged.
10. The Truetrac differential assembly is non-repairable. Discard the entire assembly if it is worn/damaged.
11. On the conventional differential assembly separate the differential case halves.
1 Match mark the case halves.
2 Remove the bolts.
3 Separate the case halves.
12. On the conventional differential assembly, remove the gear assembly.
1 Remove the thrust washer and differential side gear.
2 Remove the differential cross shaft with the pinion mates and the thrust washers.
3 Remove the differential side gear and thrust washer.
13. CAUTION: Do not use a chisel to remove the rivet heads. This will damage the differential case.
CAUTION: Use a soft hammer to strike the punch.
If discarding the pinion/differential ring gear, carefully center punch each differential ring gear rivet.
14. Drill the rivet heads to the depth shown using the specified size drill bit.
15. Separate the differential ring gear from the case.
1 CAUTION: Use a soft hammer to strike the punch.
Drive out the remaining rivet portions with a rounded type punch.
2 Separate the differential ring gear from the case.
3 CAUTION: Discard the anti-lock speed sensor ring (4B409) if separating it from the case half.
If necessary, remove the anti-lock speed sensor ring and discard it.
16. CAUTION: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum based cleaning solvent.
CAUTION: Use soft, clean, lintless towels to dry the components.
CAUTION: Never spin-dry bearings with compressed air. This will damage the mating surfaces due to a lack of lubrication.
CAUTION: After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.
NOTE: For Truetrac differentials, submerge the entire differential assembly in a suitable solvent to wash away contaminants from within the housing.
Clean and dry the components.
17. Inspect the bearing surfaces for pitting, wear and overheating.
18. Inspect the following:
- the differential case machine surfaces.
- the differential ring gear mounting holes for deformities, such as egg shaping.
- all surfaces for nicks and cracks.
19. Inspect the thrust washers for scoring and cracking.
20. CAUTION: Discard all gears in sets if one or more sustains wear/damage.
Inspect the gears for pitting, scoring, wear and damage.
21. Inspect the shafts for nicks and scores.
22. Refer to Drive Pinion if disassembly is necessary.
Assembly
1. Assemble the differential ring gear and, if removed, a new anti-lock speed sensor ring to the differential case.
1 Align the tab on the sensor ring with the notch in the case flange.
2 Bolt the differential ring gear to the case in three places, 120 degrees apart.
2. NOTE: Proceed to the next step of this procedure if not installing a new anti-lock speed sensor ring.
Press the anti-lock speed sensor ring on the case flange.
3. CAUTION: Compress the rivet before removing the bolts from the differential ring gear and case to prevent differential ring gear runout.
Install each rivet, using a suitable hydraulic or mechanical press and riveting fixture and applying the force specified.
4. CAUTION: Place the differential side bearing cups on the differential side bearings after pressing the bearings on the case. This will prevent bearing damage during the remaining assembly process.
Press the differential side bearings on the differential case halves, and place the bearing cups on the bearings.
5. NOTE: Lightly lubricate all of the mating surfaces with clean axle lubricant. This will aid in assembly and provide initial lubrication.
On the conventional differential, install the gear assembly.
1 Position the thrust washer and the differential side gear into the case half.
2 Position the differential cross shaft with the pinion mates and the thrust washers into the case half.
3 Position the differential side gear and thrust washer on the differential pinion mates.
6. CAUTION: Align the match marks.
On the conventional differential, assemble the differential case halves.
7. CAUTION: Do not damage the differential ring gear and pinion.
Using the special tool, carefully position the differential subassembly into the carrier.
8. CAUTION: The bearing cups must seat on the differential side bearings.
CAUTION: Align the match marks.
Install the differential bearing caps.
1 Position the bearing cap onto the leg.
2 CAUTION: The bolt threads must be clean.
Apply Threadlock 262 E2FZ-19554-B or equivalent meeting Ford specification WSK-M2G351-A6 to the bolt threads, and install the bolts.
Tighten the bolts enough to eliminate visible space between the bearing cap and leg. Do not tighten the bolts to the appropriate torque at this time.
9. CAUTION: Align the differential assembly within the bearing bores before applying preload or damage to the bearings will result.
Install the differential bearing adjusting rings.
- Tighten both adjusting rings until there is zero end play, and some backlash between the differential ring gear and pinion. Make sure the adjusting ring tooth aligns so that installation of the adjusting ring lock is possible.
10. Set the backlash at zero.
NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring lock is possible.
Loosen the adjusting ring on the tooth side of the differential ring gear one tooth and tighten the opposite adjusting ring one tooth. Repeat this process until backlash is at zero.
11. Set the backlash and the bearing preload to specifications.
- With a new matched set installed, set the backlash to the specification etched in the differential ring gear.
- With the original matched set installed, set the backlash to the specification recorded prior to disassembly.
NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring lock is possible.
Tighten the adjusting ring on the tooth side of the differential ring gear until backlash is within specifications.
12. Check the differential ring gear and pinion backlash in four equally spaced positions around the differential ring gear.
- The acceptable backlash tolerance is 0.0508 mm (0.002 inch) from the backlash etched in the differential ring gear.
- If the backlash tolerance varies more than 0.080 mm (0.003 inch) between the four positions, remove the differential and determine the cause.
13. Tighten the bolts.
- Check the differential ring gear and pinion backlash, as described in the previous step, after tightening the bolts.
14. Install the adjusting ring locks.
15. Install the rear anti-lock brake sensor.
16. Install the carrier.