Traction-LOK

Special Tools, Part 1 Of 3:

Special Tools, Part 2 Of 3:

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 anti-lock speed sensor ring cannot be reused once removed.





5. Use the 2-Jaw Puller for Differential Case Bearings and the Step Plate Adapter to remove the differential bearing.
^ Repeat for the other side.





6. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.





7. Remove the differential clutch spring.

WARNING: DUE TO THE SPRING TENSION, CARE MUST BE USED WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING.





8. Remove the differential gears.
1 Remove the two differential pinion gears.
2 Remove the two differential side gears.
3 Remove the two differential pinion thrust washers.





9. Remove the differential clutch packs and differential side gears and tag them "right" and "left" with the shim.
^ Clean and inspect the remaining parts of the differential case for wear or damage and replace parts as necessary.

CAUTION: Keep the differential clutch packs in order. Do not mix them. They must be reassembled in the same sequence.

10. Clean and inspect the differential clutch packs for wear and replace parts as necessary.

CAUTION: 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 additive Ford Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.

CAUTION: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the axle.





2. Assemble the differential clutch packs (without the shims) on the respective differential side gears.

CAUTION: Do not mix the differential clutch packs or shims from one side with the other.





3. Place the base portion of Traction-Lok Clutch Gauge in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge.

CAUTION: Make sure the proper mandrel is used with a Traction-Lok Clutch Gauge.





4. Position the Traction-Lok Clutch Gauge hand-tight on top of the differential clutch pack.





5. Install Top 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.

8. Remove Traction-Lok Clutch Gauge from the clutch pack and side gear assembly.
9. Install shims on the clutch pack and side gear assembly.





10. Install the differential side gear in the differential case.





11. Install the differential pinion gears with differential pinion thrust washers in the differential case.





12. Install the differential clutch spring, using a soft-faced hammer.





13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.





14. Use the Differential Side Bearing Replacer to install the differential bearing on the differential case. Repeat for the other side.





15. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case.
^ Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes properly.





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





17. Install the ring gear bolts.
^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts.

18. Install the differential case.