Operation CHARM: Car repair manuals for everyone.

Conventional


Special Tools:





DISASSEMBLY
1. Remove the differential case.





2. Remove the 10 ring gear bolts.





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

CAUTION: Care should be taken not to damage the bolt hole threads.





4. Remove the speed sensor ring if required.

NOTE: The speed sensor ring cannot be reused once removed.





5. If required, use 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter to remove the differential bearing.





6. Remove the differential pinion shaft lock bolt.





7. Remove the differential pinion shaft.





8. Rotate and remove the differential pinion gear and differential pinion thrust washer.





9. Remove the differential side gear and the differential pinion thrust washer.

ASSEMBLY





1. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washer and the differential side gear journals.
^ Position the differential side gear thrust washer on the differential side gear.





2. Position the differential side gear.





3. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washer and the differential pinion gear and assemble.





4. Engage the differential pinion gear opposite the differential side gear.





5. Rotate the differential pinion gear to align with the differential pinion shaft bore.





6. Insert the differential pinion shaft.
^ Align the hole in the differential pinion shaft with the hole in the differential case.





7. Install a new differential pinion shaft lock bolt and tighten finger-tight.

NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation.





8. Use Differential Side Bearing Replacer to install the new differential bearings on the differential case.





9. Press the new anti-lock speed sensor ring and the ring gear on the differential case.





10. Install the ring gear bolts.
^ Apply Stud and Bearing Mount EOAZ-19554-B or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts.
11. Install the differential case.