Disassembly and Assembly (With Traction-Lok)
DISASSEMBLY1. Remove and discard the 10 rear axle differential ring gear bolts securing the ring gear to the differential case.
NOTE: It is not necessary to remove the differential cone and roller assemblies from the case journals unless they are damaged. If the bearings remain on the differential case during service, keep them clean and free from foreign material.
2. Remove the ring gear by tapping the gear with a soft-faced hammer or press the gear from the differential case.
3. Remove the differential pinion shaft lock pin and remove the differential pinion shaft.
4. With a suitable drift, drive out the S-shaped differential clutch spring.
WARNING: USE CARE WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING BECAUSE OF SPRING TENSION.
5. Rotate the differential pinion gears until the differential pinion gears and differential pinion thrust washers can be removed.
6. Remove the differential side gears differential clutch packs and rear axle differential clutch shims from the 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 SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A and dip all clutch plates in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A 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. Rotate the differential pinion gears until the bores in the differential pinion gears are aligned with the differential pinion shaft holes in the differential case.
5. With a soft-faced hammer, install the S-shaped differential clutch spring in the differential case. If necessary, complete the installation of differential clutch spring with a brass drift.
NOTE: Inspect the differential clutch spring for damage.
6. Clean the tapped holes in the differential ring gear and pinion with a suitable solvent. If the new 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.).
NOTE: Do not tighten the differential pinion shaft lock pin at this point. The differential pinion shaft and differential pinion shaft lock pin will be removed to install the axle shafts. Once the axle shafts and retaining washers are installed, then the differential pinion shaft and differential pinion shaft lock pin may be installed and tightened to specification.
7. Perform Pre-load inspection.