Disassembly and Assembly

Differential Case






Disassembly

1. Remove ring gear bolts and remove ring gear from carrier.






2. Place differential case in vise and drive out lock pin that retains the differential pinion shaft to case.






3. Remove differential pinion shaft with a drift.

4. Rotate the pinion mate gears and side gears until the pinion mate gears turn to the case windows.

5. Remove a pinion mate gears and differential pinion thrust washers.






6. Lift side gears and thrust washers from case.

Assembly

1. NOTE: Always replace gears as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and short gear life.

Inspect components for wear and replace as required.

2. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A to side gear thrust washers, hub and thrust face of side gears.

3. Lubricate pinion mate gears and differential pinion thrust washer with High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A.

4. Hold side gears in place in case with one hand and install pinion mate gears and differential pinion thrust washers with other hand.

5. Rotate the side gears and pinion mate gears until holes in washers and pinion mate gears line up exactly with holes in case.

6. Insert the differential pinion shaft in the case. Align the lock pin hole in the shaft with lock pin holes in the case.

7. Insert lock pin. Note the location of the slot in the roll pin. Peen some metal of the case over the pin in two places, 90 degrees away from the slot, to lock it in place.

8. Install the ring gear and ring gear bolts. Tighten to 95-122 Nm (70-90 lb-ft).