Differential Case and Ring Gear-Traction-LOK

Special Tools:

Disassembly
1. Remove the differential case.

2. Remove the 10 bolts.

3. CAUTION: Do not damage the bolt hole threads.

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

4. CAUTION: Do not reuse the anti-lock speed sensor ring after removing it.

If necessary, remove the anti-lock speed sensor ring and discard it.

5. Using the special tools, remove the differential bearings.

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

7. WARNING: Due to the spring tension, take care when removing the differential clutch spring.

Remove the differential clutch spring.

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

9. CAUTION: Keep the differential clutch packs in order. Do not mix them. Be sure to reassemble them in the same sequence.

Remove and tag the differential clutch packs, shims and differential side gears "right" and left".

10. CAUTION: Do not use acids or solvents to clean the differential clutch packs. Wipe the components with a clean, lint-free cloth only.

Clean and inspect the differential clutch packs for wear and damage. Install new parts as necessary.
11. Clean and inspect the remaining differential case components for wear and damage. Install new components as necessary.

Assembly

1. CAUTION: Use 118 ml. (4 oz.) of Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A in the axle.

Prelubricate each steel clutch plate and soak all of the friction plates in Ford Additive Friction
Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.

2. CAUTION: Do not mix the left and right side differential clutch packs and shims.

Assemble the left and right differential clutch packs (without the shims) and differential side gears.

3. CAUTION: Use the correct mandrel with the Differential Clutch Gauge.

Place the special tool in a vise.

4. Install the differential clutch pack and differential side gear (without the shim) on the special tool.

5. Position the special tool hand-tight on top of the differential clutch pack.

6. Install the special tool over the disc and differential clutch pack.

7. Install the nut.

8. Note: Clutch Pack Kit FSAZ-4947-BA is available to rebuild the 8.8-inch ring gear Traction-Lok differential.

Using the special tool, determine the thickness of the new clutch shim.
- Insert the thickest blade that will enter between the tool and the differential clutch pack.

Selective Shims

9. Remove the special tool from the clutch pack and side gear assembly.
10. Install the shims on the clutch pack and side gear assembly.

11. Install the differential side gear assemblies in the differential case.

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

13. Using a soft-faced hammer, install the differential clutch spring.

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

15. Using the special tool, install the differential bearings.

16. Install the anti-lock speed sensor ring by aligning the tab with the slot.
- Start two 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.

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

18. Install the bolts.
- Apply Stud and Bearing Mount EOAZI9554-BA or equivalent meeting Ford specification WSK-M2G349-AI to the bolt threads.
19. Install the differential case.