Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear

Differential Case and Ring Gear

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Material:

Disassembly
1. Remove the differential carrier.
2. Remove the 10 differential ring gear bolts.





3. CAUTION: Care should be taken not to damage the differential ring gear bolt hole threads.

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





4. Using the special tools, remove the differential bearings.





5. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.
^ Discard the differential pinion shaft lock bolt.





6. WARNING: Due to the spring tension, care must be used when removing the differential clutch spring.

Remove the differential clutch spring.





7. Remove the differential gears.
1. Remove the differential pinion gear and thrust washers.
2. Remove the 2 differential side gears.





8. CAUTION: Keep the differential clutch packs in order. Do not mix the differential clutch packs. The differential clutch packs must be reassembled in the same sequence.

Remove the differential clutch packs and differential side gears and tag them "RH" and "LH" with the selective shim.
^ Clean and inspect the remaining components of the differential case for wear or damage and install new components as necessary.





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

Clean and inspect the differential clutch packs for wear or damage and install new components as necessary.

Assembly
1. Install selective shims on the clutch pack and differential side gear assembly.
2. Install the differential side gear in the differential case.





3. Install the differential pinion gears with differential pinion gear thrust washers in the differential case.





4. Using a soft-faced hammer, install the differential clutch spring.





5. NOTE: If a new differential pinion shaft lock bolt is unavailable, coat the threads of the old differential pinion shaft lock bolt with Threadlock and sealer.

Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.





6. Using the special tool, install the differential bearings on the differential case.
1. Position the differential bearing.
2. Using the special tool, press on the differential bearing.





7. Press the differential ring gear on the differential assembly.

8. NOTE: On the 5.4L applications, the differential flange and ring gear flange must be free of any old stud and bearing mount material. Failure to clean the surfaces can result in ring gear runout concerns.

Apply stud and bearing mount to the differential ring gear bolts and the rear face of the 5.4L application ring gear. Install the differential ring gear bolts.
^ Tighten 4.0L and 4.6L to 105 Nm (77 ft. lbs).
^ Tighten the 5.4L application ring gear bolts to 135 Nm (100 ft. lbs).





9. Check the torque required to rotate one differential side gear.
^ Mount the differential assembly and special tool in a vise.
^ The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.





10. Install the differential carrier.