Disassembly
NOTE: When the axle lubricant has been drained for rear axle repair (limited slip only), refill the rear axle with the specified quantity of Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2CI97-A and add 0.163 L (5.5 ounces) of Ford Friction Modifier F3TZ-19B546-MA or equivalent friction modifier meeting Ford specification WSP-M2C196-A.
1. Mark the differential case.
(1) Mark the flange (ring gear) half and button (cover) half of the differential case for reassembly in the same positions.
(2) Mark the differential pinion shafts and their corresponding ramps for reassembly in the same positions.
2. Clamp the differential in a soft-jawed vise. Insert an axle shaft into the differential to act as a holding tool. Loosen the differential case bolts. Do not remove.
3. Place the differential on the bench with the flange half of the differential case down. Remove the differential case retaining bolts and button half of the differential case.
4. Remove the differential side gear, side gear ring, and rear axle disc and plate kit. Keep these parts with the button half of the differential case to reinstall in the original positions.
5. Remove the side gear ring, clutch discs, and clutch plates from the flange half of the differential case, and keep them in their original order by placing them on the rear axle universal joint flange as shown in the illustration.
6. Inspect the entire assembly.
(1) Inspect the clutch plates and clutch discs for cracks, excessive wear, and distortion. If one or more of the clutch plates or clutch discs needs replacing, replace the entire rear axle disc and plate kit. Inspect all other parts and replace any worn or damaged part.
(2) Inspect the surfaces of the differential pinion shafts and the ramp surfaces on the differential case for excessive wear or pitting.
(3) Inspect the teeth of the differential side gears and differential pinion gears. Inspect the differential side gear races that bear on the differential side gear rings.