- Raise vehicle. Remove rear wheels and brake drums. Remove cover from axle housing and drain lubricant. Working through cover opening, remove pinion shaft lock bolt and pinion shaft.
- Push axle shafts inward until "C" locks at button end of shafts are clear of side gear recess. Remove "C" locks. Pull axle shafts out of housing.
NOTE:
Use care to avoid damaging axle seals when removing axle shafts. Shafts must be completely removed from axle housing.
- Using drift, drive "S" shaped preload spring half-way out of differential housing. Rotate differential housing 180 degrees. Hold "S" shaped preload spring with pliers and tap spring until it is removed from differential. See Fig 1
.
NOTE:
Care must be used when removing preload spring due to spring tension.
Courtesy of FORD MOTOR CO.
- Using Pinion Rotator (T84P-4205-A) for the 7 1/2" or (T80P-4205-A) for the 8 3/4" with a 12" extension, rotate pinion gears until gears can be removed from differential. Remove side gears and clutch pack with shim. Tag gears and clutch packs as left and right side. DO NOT
use cleaning solvent on clutch plate surfaces.
NOTE:
DO NOT
mix clutches or shims.
- Inspect clutch plates for uneven or extreme wear. Steel plates must be free from burrs, nicks and scratches. Internally splined clutch plates should be inspected for condition of material. Replace plates if internal teeth are worn or thickness is less than .058" (1.5 mm).
- Install Differential Clutch Gauge (T84P-4946-A for 7 1/2" or T80P-4946-A for 8 3/4") on side gear clutch pack without shim. Tighten to 60 INCH lbs. (6.7 N.m). Using feeler gauge, select thickest blade that will enter between clutch gauge and clutch pack. See Fig 2
. This reading will be thickness of new shim for that clutch pack. Repeat procedure for opposite clutch pack.