9.75" & 10.25" Differential
- Install Traction Lock Torque Tool (T97T-4205-A) in a vise. Install side gears with differential clutch packs, shims and Belleville spring washers into differential case. Position carrier on Torque Tool. Hold upper side gear in place to keep it from falling out. Apply grease to Step Bore Plate and assemble Mandrel and forcing screw in between side gears. See Figure .
- Lubricate both sides of pinion gear thrust washers with Motorcraft Synthetic Axle Lubricant (F1TZ-19580-B) or equivalent. Place differential pinion gears and thrust washers in carrier windows, 180 degrees apart, on side gears. Install pinion gear rotator handle into pinion gear hole of differential case. Rotate case until pinion gears are aligned with pinion shaft hole. Remove rotator handle from differential case.WARNING: Keep fingers and hands clear of pinion gears while rotating differential case.
- Remove forcing screw, Mandrel and Step Bore Plate from differential case. Install pinion shaft and pinion shaft lock bolt. DO NOT tighten pinion shaft lock bolt at this time. Before installing differential case in axle housing, bench-test differential case clutch packs using Traction-Lok Torque Adapter (T59L-4204-A). With differential carrier positioned on Torque Tool in vise, install second Torque Tool in upper side gear. See Figure .
- Measure torque required to turn side gear. This checks torque required to rotate one side gear while other is held stationary. If clutch plates are used, break-away torque should be at least 20 ft. lbs. (27 N.m) and rotation should be smooth. If clutch plates are new, break-away torque may vary and be slightly higher than specification. If break-away torque (torque required to rotate side gear) is not at least 20 ft. lbs. (27 N.m) or rotation is not smooth, different shim must be installed in clutch pack.
- If break-away torque is as specified and rotation is smooth, tighten pinion shaft lock bolt to proper specification. See TORQUE SPECIFICATIONS .