Differential Case and Ring Gear - Traction-Lok(R)

Differential Case and Ring Gear - Traction-Lok(R)

Special Tool(s):

Material:

Initial disassembly

NOTE: If the Diagnostic Chart directed the servicing of the Traction-Lok(R) clutch packs, it is not necessary to remove the differential carrier assembly from the axle housing. Proceed to Step 7.

NOTE: If the differential ring gear backlash between teeth is greater than specification, remove the ring gear to check the differential case flange runout. Do not disassemble the differential carrier assembly.

1. Remove the differential carrier. Tag the differential shims and bearing cups for location.
2. Remove the 10 differential ring gear bolts.

3. CAUTION: Care should be taken not to damage the differential ring gear bolt hole threads.

Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.

4. If checking differential case flange runout, install the bearing cups in their original location and install the differential assembly.
1 Install the bearing caps and differential shims.
^ Rotate the differential assembly to verify the bearings have seated.

2 Install the special tool and record the differential case runout.

Final disassembly

5. NOTE: The anti-lock ring cannot be reused once removed.

If necessary, remove the anti-lock ring.

6. Using the special tools, remove the differential bearings.

7. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.

8. WARNING: Due to the spring tension, care must be used when removing the differential clutch spring.

Remove the differential clutch spring.

9. Remove the differential gears.
1 Remove the 2 differential pinion gears.
2 Remove the 2 differential side gears.
3 Remove the 2 differential pinion thrust washers.

10. CAUTION: Keep the differential clutch packs in order. Do not mix the differential clutch packs. The differential clutch packs must be reassembled in the same sequence.

Remove the differential clutch packs and differential side gears and tag them "RH" and "LH" with the selective shim.
^ Clean and inspect the remaining components of the differential case for wear or damage and install new components as necessary.

11. 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 or damage and install new components as necessary.

Assembly

1. CAUTION: Use 118 ml (4 ounces) of the specified friction modifier in the axle.

Pre-lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.

2. CAUTION: Do not mix the differential clutch packs or selective shims from one side with the other.

Assemble the differential clutch packs (without the selective 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 selective 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 differential clutch pack.

6. Install the nut of the gauge over the top and base stud.
^ Tighten to 6.7 Nm (60 inch lbs.).

7. NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit F5AZ-4947-BA.

Use the 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 selective shim.

Selective Shims:

8. Remove the special tool from the clutch pack and differential side gear assembly.
9. Install selective shims on the clutch pack and differential side gear assembly.
10. Install the differential side gear in the differential case.

11. Install the differential pinion gears with differential pinion gear thrust washers in the differential case.

12. Using a soft-faced hammer, install the differential clutch spring.

13. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with threadlock 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 assembly 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 bearings on the differential case.

16. Position the differential ring gear, the new anti-lock speed sensor ring and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and into the differential ring gear.

17. NOTE: Apply stud and bearing mount to the differential ring gear bolts.

Install the differential ring gear bolts.
^ Tighten to 105 Nm (77 ft. lbs.).

18. Install the differential carrier.