Differential Case and Ring Gear - Traction-Lok(R)

Differential Case and Ring Gear - Traction-Lok(R)














Traction-Lok(R) Differential Assembly









Disassembly

1. Remove the differential carrier. Tag the differential shims and bearing cups for location. For additional information, refer to Differential Carrier Differential Carrier.

2. Remove and discard the 12 differential ring gear bolts.





3. NOTICE: Care should be taken not to damage the differential ring gear bolt hole threads.

Insert a punch in the differential ring gear bolt holes. Drive off the differential ring gear.





4. If checking differential case flange runout, install the bearing cups in their original location and install the differential assembly.

1. Install the bearing caps and differential shims.
- Rotate the differential assembly to verify the bearings have seated.

2. Install the Dial Indicator Gauge With Holding Fixture and record the differential case runout.





5. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential.

If necessary, use the 2 Jaw Puller and Step Plate to remove the differential bearings.





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





7. Install the Differential Gauge in a suitable vise.





8. Install the differential case on the Differential Gauge.





9. NOTE: Apply a small amount of grease to the centering hole of the Differential Gauge.

Install the Differential Gauge in the bottom differential side gear.





10. 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.





11. NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened.

Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gears away from the differential pinion gears.





12. NOTE: Differential pinion gear thrust washers cannot be removed independently of the differential pinion gears.

Insert the Differential Rotator in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential pinion gear thrust washers out to the differential case windows.





13. Remove the differential pinion gears and differential pinion gear thrust washers.





14. Remove the differential side gears and differential clutch packs with the selective shim and Belleville spring, tag them RH and LH.





15. NOTE: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence.

NOTE: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only.

Separate the differential clutch discs and clutch plates for cleaning and inspection.





Assembly

All vehicles

1. Lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.





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

NOTE: The Belleville spring is a dished plate.

Assemble the differential clutch packs (without the selective shims and Belleville springs) on their respective differential side gears.





3. Clamp the bolt head of the Differential Gauge in a vise. Install the differential clutch pack and the differential side gear (without the selective shim or the Belleville spring) on the Differential Gauge.





4. Position the Differential Clutch Gauge on top of the differential clutch pack.





5. Install the Differential Gauge over the disc and differential clutch pack.





6. Install the nut over the top and base stud.
- Tighten to 7 Nm (62 lb-in).





7. NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit.

Use the feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack. Subtract 0.0075" from the reading, Then select the closest thinner thickness selective shim, that will be the new selective shim that should be used.





8. Place the selective shim and Belleville spring on the differential clutch pack.
- The dished or concave side of the Belleville spring must face up against the thrust face of the differential case.





9. Install the differential side gears with the differential clutch packs, selective shims and Belleville spring into the differential case.
- Hold the differential side gear assembly in place to prevent it from falling out of the differential case.





10. NOTE: Apply a small amount of grease to the step plate bore.

NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.

Assemble the Differential Gauge to the differential case.

1. Position the Differential Gauge in the bottom differential side gear.

2. Position the Differential Gauge in the top differential side gear and hold it in place.

3. Install the Differential Gauge and tighten it 2 turns after it contacts the bottom step plate.





11. NOTE: Lubricate both sides of the differential pinion gear thrust washers with axle lubricant.

NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.

Position the differential pinion gears and differential pinion gear thrust washers in the window of the differential case so they mesh with the differential side gear teeth.





12. 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.

Insert the Differential Rotator 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 shaft mating holes are lined up exactly with the holes in the differential pinion gears.





13. Remove the Differential Gauge.

14. NOTE: If a new differential pinion shaft lock bolt is unavailable, coat the threads of the original differential pinion shaft lock bolt with threadlock prior to installation.

Install the differential pinion shaft, then a new differential pinion shaft lock bolt finger-tight.





15. Install the 2 new differential bearings using the Differential Carrier Bearing Installer.





16. Check the torque required to rotate one differential side gear.
- Install the Differential Gauge with the 1/2-inch drive hole as shown.

- The initial break-away torque, if original clutch plates are used, must be at least the minimum specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.





SVT vehicles

17. NOTE: The differential flange and ring gear flange must be free of any old retaining compound material. Make sure both surfaces are clean and free of oil, dust and debris. Failure to clean the surfaces can result in ring gear runout concerns.

Clean all traces of the old retaining compound material from the differential flange.

- Use solvent and Scotch-Brite(R) pads to remove.

18. Apply a one-eighth inch bead of maximum strength retaining compound on the rear face of the ring gear in the pattern shown.





All vehicles

19. Using a suitable press, install the differential ring gear.





20. Install the new 12 differential ring gear bolts.
- Tighten to 150 Nm (111 lb-ft).





21. Install the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.