Differential Assembly: Service and Repair
DISASSEMBLY1. NOTE: It is not necessary to remove the differential bearings 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.
Remove and discard the 10 rear axle differential gear case bolts securing the ring gear to the differential case assembly.
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.
Special Tool:
4. WARNING: USE CARE WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING DUE TO SPRING TENSION.
With a suitable drift, drive out the S-shaped, pre-loaded differential clutch spring.
5. Using Gear Rotator 205-134 (T80P-4205-A), 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. NOTE: Do not use cleaning solvents on friction plate surfaces. Wipe clean only.
Clean and inspect all parts for wear or damage; replace as necessary.
8. Adjust clutch pack preload.
ASSEMBLY
1. Lubricate all parts with Premium Rear Axle Lubricant XY-80W90-01 or equivalent meeting Ford specification WSP-M2C197-A. Soak all friction plates in Additive Friction Modifier C8AZ-1913546-A or equivalent meeting Ford specification EST-M2C118-A for at least 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 205-134 (T80P-4205-A) in the differential case.
5. Rotate the differential pinion gears until the bores in the differential pinion gears are aligned with the pinion shaft holes in the differential case. Remove the tool from the differential case.
6. NOTE: Inspect the differential clutch spring for damage.
With a soft-faced hammer, install the S-shaped, pre-loaded differential clutch spring in the differential case. If necessary, complete the installation of S-shaped, pre-loaded differential clutch spring with a brass drift.
7. Install the differential pinion shaft. Align the hole in the shaft with the hole in the differential case.
8. NOTE: Install but 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. After the axle shafts are installed, re-install the differential pinion shaft and the differential pinion shaft lock pin. Tighten to 20-41 Nm (15-30 ft. lbs.).
If the new rear axle differential gear case 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.).