Disassembly and Assembly (With Traction-Lok)
DISASSEMBLY1. Remove and discard 10 rear axle differential gear case bolts, retaining ring gear to differential case.
NOTE: It is not necessary to remove the differential bearings from the differential case journals unless they are damaged. If the differential bearings remain on the differential case during service, keep them clean and free from foreign material.
2. Remove ring gear by tapping with a soft-faced hammer or press gear from differential case.
3. Remove differential pinion shaft lock pin and remove differential pinion shaft.
4. With a suitable drift, drive out the S-shaped pre-loaded differential clutch spring. Hold differential clutch spring with pliers and tap differential clutch spring until it is removed from the differential case.
WARNING: USE CARE WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING BECAUSE OF SPRING TENSION.
5. Using Gear Rotator, rotate differential pinion gears until differential pinion gears and differential pinion thrust washers can be removed.
6. Remove differential side gears, differential clutch packs and rear axle differential clutch shims from RH and LH cavities and tag them "RH" and "LH."
7. Clean and inspect all parts for wear or damage. Replace as necessary.
NOTE: Do not use cleaning solvents on friction plate surfaces. Wipe clean only.
8. Adjust clutch pack preload.
ASSEMBLY
1. Lubricate all parts with Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A. Soak all friction plates in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for 15 minutes prior to assembly.
2. Mount the differential case in a soft-jaw vise and place the differential clutch packs and differential side gears in their proper cavities in the differential case.
3. Place the differential pinion gears and differential pinion thrust washers on the differential side gears.
4. Install Gear Rotator in the differential case.
5. Rotate differential pinion gears until the bores in the differential pinion gears are aligned with differential pinion shaft holes in the differential case. Remove tool from differential case.
6. With a soft-faced hammer, install the S-shaped, pre-loaded differential clutch spring in the differential case. If necessary, complete installation of S-shaped, pre-loaded differential clutch spring with a brass drift.
NOTE: Inspect the differential clutch spring for damage.
7. Install the differential pinion shaft and differential pinion shaft lock pin and tighten to 20-41 Nm (15-30 ft. lbs.).
NOTE: Differential pinion shaft lock pin should be replaced with a new differential pinion shaft lock pin. If 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.
8. Clean tapped holes in ring gear with a suitable solvent. If the new rear axle differential ring gear bolts to be used show a green coating over approximately 12.7 mm (1/2 inch) of the threaded area, use as is. If not coated, apply a small amount of Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1. Tighten to 95-115 Nm (70-84 ft. lbs.).
9. Install the differential case and ring gear.