Ford 8.8-Inch Ring Gear - Rear Drive Axle/Differential
Differential Case and Ring Gear Traction-Lok(R)
Disassembly
1. Remove the differential assembly from the differential housing.
2. Remove and discard the 10 differential ring gear bolts.
3. NOTE: Do not damage the bolt hole threads.
NOTE: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during assembly.
Insert a punch in the bolt holes and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring.
4. Using the special tools, remove the 2 differential bearings.
5. CAUTION: Due to the spring tension, use care when removing the differential clutch spring or damage to the component may occur.
Remove the differential clutch spring.
6. Remove the differential gears.
1 Remove the 2 differential pinion gears.
2 Remove the 2 differential side gears.
3 Remove the 2 differential pinion thrust washers.
7. NOTE: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence.
Separate the differential clutch packs and shims from the differential side gears and tag them "right" and "left."
^ Clean and inspect the remaining differential components for wear and damage and install new parts as necessary.
8. NOTE: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the components only with a clean, lint-free cloth.
Clean and inspect the differential clutch packs for wear and damage and install new parts as necessary.
Assembly
1. NOTE: Use 118 ml (4 oz) of the friction modifier in the axle.
Lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes with friction modifier.
2. NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.
Assemble the differential clutch packs (without the shims) on their respective differential side gear.
3. Place the base portion of the special tool in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool.
4. Position the special tool hand-tight on top of the differential clutch pack.
5. Install the special tool over the disc and differential clutch pack.
6. Install the nut.
^ Tighten to 6.7 Nm (60 lb-inch).
7. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.
Selective Shims
Selective Shims:
8. Remove the special tool from the differential clutch pack and differential side gear assembly.
9. Install the shim(s)) on the differential clutch pack and differential side gear assembly.
10. Install the differential side gear assemblies in the differential case.
11. Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case.
12. Using a soft-faced hammer, install the differential clutch spring.
13. NOTE: If a new bolt is unavailable, coat the threads with Threadlock(R) prior to installation.
Install the differential pinion shaft and install a new bolt finger-tight.
14. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
^ If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.
15. Using the special tool, install the differential bearings.
16. Position the differential ring gear, the anti-lock speed sensor ring and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case.
17. Install the 10 new differential ring gear bolts.
^ Tighten to 105 Nm (77 lb-ft).
18. Install the differential assembly.