Differential Assembly: Adjustments

In-vehicle adjustments are possible on this unit without removing the differential case from the rear axle assembly. If the testing check was not to specification, use the following procedure to correct the condition:





1. Raise the vehicle on a hoist and install safety stands. Remove rear wheels, rear disc brake calipers and rear disc brake rotors.

NOTE: Whenever replacing the rear axle lubricant, use SAE 80W90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A and Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.

2. Remove axle housing cover from differential case face and drain lubricant.
3. Perform inspection before disassembly. Replace any worn or damaged parts.
4. Working through the cover opening, remove the differential pinion shaft lock pin and remove the differential pinion shaft.
5. Push axle shafts inward until the U-washers at the button end of shafts are clear of the differential side gear recess.





6. Remove the u-washers and pull the axle shafts out of the rear axle housing.

CAUTION: Do not damage the inner wheel bearing oil seals when removing the axle shafts from the axle housing. The axle shafts must be completely removed from the axle housing.
7. With a suitable drift, drive the S-shaped differential clutch spring half-way out of the differential case. Rotate the differential case 180 degrees.

WARNING: USE CARE WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING BECAUSE OF SPRING TENSION.





8. Hold the differential clutch spring with a pair of pliers and tap the differential clutch spring until it is removed from the differential case.
9. Rotate the gears by hand until they can be removed through the opening in the differential case.
10. Remove the RH and LH differential side gear and differential clutch pack with the rear axle differential clutch shim and tag them " RH" and "LH."
11. Inspect the differential clutch packs for wear and replace as necessary.

NOTE: Do not use cleaning solution on clutch plate surfaces. Wipe clean only.

12. Mount Traction-Lok Clutch Gauge (T80P-4946-A) in vise and install the differential side gear differential clutch packs without the rear axle differential clutch shim. Tighten to 6.7 Nm (60 inch lbs.).
13. Place the differential pinion gears and differential pinion thrust washers 180 degrees apart on the differential side gears.
14. Rotate differential pinion gears until they are aligned with the differential pinion shaft hole.
15. Hold the differential clutch spring up to the differential case window. Using a soft-faced hammer, hammer the differential clutch spring into position.

NOTE: Inspect the differential clutch spring for damage.

16. Install the axle shafts and U-washers into position. Push the axle shaft outboard as far as possible.
17. Install differential pinion shaft so hole in shaft aligns with case lock pin hole.
18. Install the differential pinion shaft lock pin. Tighten differential pinion shaft lock pin to 20 - 41 Nm (15 - 30 ft. lbs.)

NOTE: Differential pinion shaft lock pin should be replaced with a new pin. If a new differential pinion shaft lock pin is not available, coat threads with Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 and tighten to specification.

19. Install the rear disc brake rotors, rear disc brake calipers and wheels. Perform the Traction-Lok Operational Check to make sure the unit is within specification.
20. Using Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESE-M4G195A install the rear axle housing cover assembly and bolts. Tighten to 34 - 47 Nm (25 - 34 ft. lbs.).

CAUTION: Make sure carrier face and axle housing cover are clean and free of old sealant before installing new silicone sealant. Axle housing cover must be installed within 15 minutes of applying sealant.

21. Add 118 ml (4.0 oz) of Additive Friction Modifier C8AZ- 19B546-A or equivalent meeting Ford specification EST-M2C118-A. Fill with SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A, 6 to 14 mm (1/4 to 9/16 inch) from the bottom of the fill hole with the axle in the running position. Install the oil filler plug. Tighten to 20 - 41 Nm (15 - 30 ft. lbs.).