Differential Case and Ring Gear - Traction-LOK

Differential Case and ring gear - Traction-Lok





Special tools

Disassembly

1. Remove the differential assembly from the differential housing.





2. Remove the bolts, if differential ring gear removal is necessary.





3. Caution: Do not damage the threads in the bolt holes.

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





4. CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly.

Remove the anti-lock speed sensor ring, if necessary.





5. Using the special tools, remove the differential bearings, if necessary.





6. Remove the bolt and the differential pinion shaft.





7. NOTE: Do not clamp the special tool that has the 1/2-inch drive hole in it in the vise.

Position the special tool (without the 1/2 drive hole) in a suitable vise.





8. Position the differential case on the special tool.





9. Assemble the special tool in the differential case.
1 Position the step plate in the bottom side gear bore. Apply a small amount of grease to the centering hole in the tool.
2 Position the nut in the top side gear bore and hold it in place.
3 Install the hex-head screw. Tighten the hex-head screw until it contacts the step plate.





10. NOTE: Use a dowel rod to keep the nut from turning while tightening the hex-head screw.

Insert a dowel rod in the hole in the nut. Tighten the hex-head screw to force the differential side gears away from the differential pinion gears.





11. WARNING: Keep fingers and hands away from the differential pinion gears when rotating the differential case with the special tool.

NOTE: Remove each differential pinion thrust washer and differential pinion gear together as an assembly.

Insert the special tool in the pinion shaft bore, and rotate the differential case to position the differential pinion gear and differential pinion thrust washer assemblies in the differential case windows.





12. Remove the differential pinion gear and differential pinion thrust washer assemblies through the differential case windows.





13. Remove the special tools, and remove each differential side gear, differential clutch pack, and shims together as an assembly from the differential case.





14. Tag the assemblies RIGHT and LEFT.





15. CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they disassemble. Reassemble them in the same sequence.

CAUTION: 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.
^ Refer to the disassembled view of the limited slip differential case.

Assembly





1. Lubricate each steel clutch plate and soak all friction plates in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.





2. NOTE: Do not mix the differential clutch packs and 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 their respective differential side gears.





3. Clamp the bolt head of the special tool in a vise.
^ Position the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the special tool.





4. Position the special tool on top of the differential clutch pack.





5. Position the special tool over the disc and differential clutch pack.





6. Install the nut from the special tool.








7. NOTE: The shims are available as part of Clutch Pack Replacement Kit F75Z-4947-AA.

Select the thickest feeler gauge blade that will enter between the special tool and the, differential clutch pack. Subtract 0.25 mm (0.010 inch) from the reading to obtain the thickness of the new clutch shim. Using no more than two shims, select the correct size shim(s) for installation. Remove the special tools.





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





9. Install the differential clutch packs with the shims and Belleville springs and differential side gears into the differential case.
^ Hold the upper 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 centering hole in the step plate.

NOTE: If necessary, insert the dowel rod in the nut bore to keep the nut from turning while tightening the hex-head screw.

Assemble the special tool 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. Tighten the hex-head screw two turns after it contacts the step plate.





11. NOTE: Lubricate both sides of the differential pinion thrust washers with SAE 75W-140 High Performance Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.

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

Position the differential pinion gear and differential pinion thrust washer assemblies in the differential case windows so that they mesh with the differential side gear teeth.





12. WARNING: Keep fingers and hands away from pinion gears when rotating the differential case with the special tool.

NOTE: Loosen or tighten the hex-head screw, as necessary, to allow the differential pinion gears and differential side gears to rotate.

Insert the special tool into the pinion shaft bore, and rotate the differential case until the pinion shaft holes in the differential case align with the pinion shaft holes in the differential pinion gears.





13. Remove the special tool from the differential case.





14. Remove the special tool from the differential case.





15. Install the differential pinion shaft in the differential case. Install the new bolt finger-tight.





16. Using the special tool, install the differential bearings, if removed.





17. NOTE: Do not clamp the special tool that has the 1/2-inch drive hole in it in the vise.

Using the special tool, check the torque necessary to rotate one differential side gear.
^ If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.





18. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring.

If removed, position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case.





19. Install the bolts.
^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-AI to the bolt threads.

20. Install the differential case.