Disassembly (Models 44 IFS, 44 IFS-HD & 60-1U)
- Remove ring gear. Remove roll pin or lock screw retaining cross shaft. Remove cross shaft using hammer and drift (by hand on 60-1U). Position Step Plate (T83T-4205-A4
) onto bottom side gear. See Fig 1. Apply grease to centering hole of step plate.
- Install Forcing Nut (T83T-4205-A2
) and Forcing Screw (T83T-4205-A3
) into differential case. See Fig 2. Guide forcing screw into step plate. Lightly tighten forcing screw. This will move side gears away from pinion gears and relieve the normal loaded condition. Using a .030" (.76 mm) thick shim or piece of gauge stock, push out spherical thrust washers. See Fig 3.
Courtesy of FORD MOTOR CO.
Courtesy of FORD MOTOR CO.
- Momentarily loosen forcing screw (this is very important as it relieves pressure on clutch pack). Retighten forcing screw until a very slight movement of pinion gears is seen. Insert Handle (T83T-4205-A1
) into pinion mate shaft bore. Handle is used to rotate differential case.
- Rotate differential case until pinion gears can be removed through large opening of differential case. When attempting to rotate side gear, it may be necessary to tighten or loosen forcing screw to permit gear movement.
- While holding top side gear and clutch pack in case by hand, remove forcing screw and handle. Remove top side gear and clutch pack. Keep clutch pack discs and plates in exact order. Turn differential case over so ring gear side is up.
- Remove step plate, other side gear and clutch pack. Remove retainer clips from both clutch packs. Separate discs and plates for cleaning and inspection. Replace complete clutch pack, even if only one component is defective.