Differential Case and Ring Gear - One-Piece, Traction-Lok(R)

Differential Case and Ring Gear - One-Piece, Traction-Lok(R)









Disassembly

1. Remove the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.

2. Remove and discard the 12 ring gear bolts.





3. Insert a punch and drive off the ring gear.





4. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential.

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

If required, remove the anti-lock speed sensor ring.

5. Remove and discard the differential pinion shaft lock bolt.





6. Remove the differential pinion shaft.





7. Install the Differential Clutch Preload Gauge in a suitable vise.





8. Install the differential case on the Differential Clutch Preload Gauge.





9. NOTE: Apply a small amount of grease to the centering hole of the Limited Slip Differential Rotator.

Install the Limited Slip Differential Rotator in the bottom side gear bore.





10. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the step plate.





11. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. The dowel bar is used to keep the nut from turning when the forcing screw is tightened.





12. NOTE: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool.

NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears.

Insert the Differential Rotator in the pinion shaft bore and turn the differential case to "walk" the differential pinion gears and differential pinion thrust washers out to the differential case windows.





13. Remove the differential pinion gears and differential pinion thrust washers.





14. Remove the differential side gears and differential clutch packs with the shims and tag them RH and LH.





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

NOTE: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only.

Separate the differential clutch discs and clutch plates for cleaning and inspection.





Assembly

1. Prelubricate each steel clutch plate and soak all friction plates in friction modifier.





2. NOTE: 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. Clamp the bolt head of the Differential 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 Differential Clutch Gauge on top of the differential clutch pack.





5. Install the Differential Clutch Gauge 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 lb-in).





7. 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.













8. Place the shim and Belleville spring on the differential clutch pack.
- The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case.





9. Insert the differential clutch packs, the selected shims, Belleville springs and differential side gears into the differential case.
- Hold the upper differential clutch pack and side gear assembly in place to prevent it from falling out of the differential case.





10. NOTE: Apply a small amount of grease to the Step Plate bore.

NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.

Assemble the Limited Slip Differential Rotator in the differential case.

1. Position the Step Plate in the bottom side gear bore.

2. Position the nut in the top side gear bore and hold it in place.

3. Install the hex-head screw and tighten it 2 turns after it contacts the bottom Step Plate.





11. NOTE: Prelubricate both sides of the differential pinion thrust washers with clean rear axle lubricant.

NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.

Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth.





12. NOTE: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool.

NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.

Insert the Differential Rotator into the pinion shaft bore and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears.





13. Install the differential pinion shaft in the differential case.





14. Install a new differential pinion shaft lock bolt.
- Tighten to 30 Nm (22 lb-ft).





15. Check the rotational torque required to rotate one differential side gear.
- Install the Differential Clutch Preload Gauge with the (1/2-inch drive hole) as shown.

- The initial break-away torque, if 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 12 new ring gear bolts.
- Tighten to 150 Nm (111 lb-ft).





17. Install the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.