Assembly

1. Place the differential side gear ring from the flange half of the differential case on the rear axle universal joint flange approximately 4 inches above the bench. Coat the clutch plates with axle lubricant, Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A and Ford Friction Modifier F3TZ-19B546-MA or equivalent meeting Ford specification WSP-M2C196-A.

CAUTION: The clutch packs (without radial grooves) must be soaked for 20 minutes in Ford Friction Modifier F3TZ-19B546-MA or equivalent meeting Ford specification WSP-M2C196-A before assembly.





2. Assemble the (A) clutch plates, (B) clutch discs, (C) side gear ring and (D) differential side gear in the (E) flange half of the differential case in order, according to the illustration.

NOTE: After assembly, make sure that the side gear splines engage the clutch pack splines and the differential side gear is fully seated.








3. Assemble the (A) clutch plates, (B) clutch discs and (C) side gear ring on the (D) differential side gear according to the arrangement shown for the (E) button half of the differential case. Align the clutch pressure plate lugs, and install into the differential case.

NOTE: There may be circumstances of continuing chatter/bumping in turns despite replacement of parts and lubricant, particularly in vehicles operating at close to GVW rating. Typical situations are emergency vehicles and fifth wheel trailers. In these cases, it is permissible to reassemble the rear axle disc and plate kit with the clutch disc adjacent to the differential side gear ring, resulting in two clutch plates together. This results in three friction surfaces instead of the normal five, lowering the torque to rotate the wheel by 40 percent.





4. Assemble the pinions and gears inside the differential case.
- Place the differential pinion shaft and differential pinion gears with the markings on the button half of the differential case.
- Install the other differential pinion shaft and differential pinion gears on the flange half of the differential case. Align the markings.






5. Assemble the differential case.
(1) Place the button half of the differential case over the assembly. Align differential case marks.
(2) Install the differential case bolts and turn each one on a few threads.

NOTE:The bolts must be clean and dry.

(3) With the axle shafts in position, tighten the differential case bolts evenly and alternately to specification. If bolt heads have "180" or seven radial lines (Grade 9) stamped on them, tighten the differential case bolts to the appropriate specification.

6. If the assembly has been properly assembled, each differential pinion shaft should be tight on its ramp. If there is clearance between the differential pinion shaft and the ramp, it must be not more than 0.254 mm (0.010 inch) and equal at all four ends of the differential pinion shafts.