Differential Case and Ring Gear -Traction-LOK

Differential Case and Ring Gear-Traction-Lok





Part 1 of 2





Part 2 of 2

Special Tool(s)

Disassembly

1. Remove the differential assembly from the differential housing.





2. Remove the bolts.





3. CAUTION: Do not damage the threads in the bolt holes.

CAUTION: 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 differential bearings, if necessary.





5. Remove the bolt and remove the differential pinion shaft.





6. WARNING: Due to the spring tension, use care when removing the differential clutch spring. Failure to follow these instructions may result in personal Injury.

Remove the differential clutch spring.
7. 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.





8. CAUTION: 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.

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

Lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes.
^ Use Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.





2. CAUTION: 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. CAUTION: Use the correct mandrel with the special tool.

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.





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

8. Remove the special tools from the differential clutch pack and differential side gear assembly.
9. Install the shim(s3 on the 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 and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G35 1-A5 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, if removed.





16. CAUTION: If installing a new anti-lock speed sensor ring, align the notch-on the case flange and the tab on the anti-lock speed sensor ring.

Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two 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 bolts.
^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to bolt threads.

18. Install the differential assembly.