Traction-LOK
Special Tools:
Special Tools, Part 2 Of 2:
DISASSEMBLY
1. Remove the differential case.
2. Remove the differential pinion shaft lock bolt, and remove the differential pinion shaft.
^ If required, remove the ring gear and anti-lock speed sensor ring.
NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter. The anti-lock speed sensor ring cannot be reused once removed.
3. Install the Traction-Lok Torque Tool in a suitable vise.
4. Install the differential case on the tool.
5. Install the Step Plate Adapter in the bottom side gear bore. Apply a small amount of grease to the centering hole of the Step Plate Adapter.
6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Step Plate Adapter.
7. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. The dowel bar is used to keep the nut from turning when the forcing screw is tightened.
8. Insert the Limited Slip Differential Rotating Tool in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential pinion thrust washers out to the differential case windows.
WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING THE DIFFERENTIAL CASE WITH THE DIFFERENTIAL ROTATING TOOL.
NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears.
9. Remove the differential pinion gears and differential pinion thrust washers.
10. Remove the differential side gears and differential clutch packs, and tag them RIGHT and LEFT with the shim.
11. Separate the differential clutch discs and clutch plates for cleaning and inspection.
CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence. Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only.
ASSEMBLY
1. Prelubricate each steel clutch plate and soak all friction plates with 236.5 ml (8 ounces) Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.
2. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.
NOTE: Do not mix the differential clutch packs or shims from one side with the other. The Belleville spring is a dished plate.
3. Clamp the bolt head of the Traction-Lok Clutch Gauge in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.
NOTE: Use the Traction-Lok Clutch Gauge Mandrel for the procedure.
4. Position the Traction-Lok Clutch Gauge on top of the differential clutch pack.
5. Install the Traction-Lok Clutch Gauge over the disc and differential clutch pack.
6. Install the nut of the gauge over the top and base stud.
7. Use the Feeler Gauge and select the thickest blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. Select the correct shim size, and remove the Traction-Lok Clutch Gauge.
8. Place the shim and Belleville spring on the differential clutch pack.
^ The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case.
9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case.
^ Hold the upper differential clutch pack and side gear assembly in place to prevent it from falling out of the differential case.
10. Assemble the forcing screw, nut and step plate to the differential case.
1 Position the step plate in the bottom side gear bore.
2 Position the nut in the top side gear bore and hold it in place.
3 Install the hex-head screw and tighten it two turns after it contacts the bottom step plate.
NOTE: Apply a small amount of grease to the step plate bore. If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.
11. Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth.
NOTE: Prelubricate both sides of the differential pinion thrust washers with Premium Synthetic Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.
12. Insert the rotating handle into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears.
WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING THE DIFFERENTIAL CASE WITH THE DIFFERENTIAL ROTATING TOOL.
NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.
13. Loosen the forcing screw, and remove the step plate and nut from the side gear bores. Install the differential pinion shaft in the differential case.
^ Install a new differential pinion shaft lock bolt finger-tight.
14. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts.
15. Replace the differential bearings, if removed.
16. Install the differential case.