Differential Case and Ring Gear - Model 60, Limited Slip: Disassembly

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: When refilling the axle with lubricant, first add 0.15L (6 oz.) of friction modifier.

NOTE: It is not necessary to remove the differential bearings to overhaul the limited-slip differential.

NOTE: In most cases it is possible to disassemble the unit without removing the differential ring gear, which saves the cost of new bolts.

If necessary, remove the 12 differential ring gear bolts and gear.

Fig 1: Locating Differential Ring Gear Bolts & Gear

Courtesy of FORD MOTOR CO.

NOTE: An axle shaft held in a vise, with the shaft splines extending not more than 76.2 mm (3 in) above the vise jaws, makes an excellent holding fixture for the differential case.

Remove the differential pinion shaft lock pin.

Fig 2: Locating Differential Pinion Shaft Lock Pin

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Using a hammer and drift, remove the differential pinion shaft.

Fig 3: Removing Differential Pinion Shaft Using A Hammer & Drift

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Position the Step Plate in the bottom differential side gear bore.
- Apply a small amount of grease to the Step Plate centering hole.

Fig 4: Positioning Step Plate In Bottom Differential Side Gear Bore

Courtesy of FORD MOTOR CO.

Screw the Limited Slip Preload Tool into the step plate.

Fig 5: Screwing Limited Slip Preload Tool Into Step Plate

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NOTE: Do not overtighten the Limited Slip Preload Tool. Overtightening can damage the rear axle disc and plate kit.

Tighten the Limited Slip Preload Tool enough to move the differential side gears away from the differential pinion gears and relieve the normal loaded condition.

Fig 6: Screwing Limited Slip Preload Tool Into Step Plate

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Using a 0.762 mm (0.030 in) thick piece of shim or gauge stock, push the differential pinion thrust washers out from behind the differential pinion gears and remove them.

NOTE: Carrying out this step releases pressure from the rear axle disc and plate kit.

Loosen the Limited Slip Preload Tool.

Fig 7: Screwing Limited Slip Preload Tool Into Step Plate

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NOTE: When attempting to rotate the differential side gears, tighten or loosen the Limited Slip Preload Tool as necessary to permit gear movement.

Tighten the Limited Slip Preload Tool until the differential pinion gears move slightly.

Fig 8: Screwing Limited Slip Preload Tool Into Step Plate

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Insert the Rotating Handle into the differential pinion shaft bore. Rotate the differential case to position the differential pinion gears in the large differential case openings. Remove the differential pinion gears.

Fig 9: Inserting Rotating Handle Into Differential Pinion Shaft Bore

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Hold the top differential side gear and rear axle disc and plate kit in the differential case and remove the Limited Slip Preload Tool.

Fig 10: Holding Top Differential Side Gear & Rear Axle Disc & Plate Kit In Differential Case

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Continue to hold the differential side gear and the rear axle disc and plate kit and remove the Rotating Handle.

Fig 11: Continuing To Hold Differential Side Gear & Rear Axle Disc & Plate Kit & Removing Rotating Handle

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Remove the top differential side gear and the rear axle disc and plate kit.

Fig 12: Removing Top Differential Side Gear & Rear Axle Disc & Plate Kit

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Turn the differential case so that the flange or differential ring gear side is facing upward. Ease the Step Plate, differential side gear and rear axle disc and plate kit out of the differential case.

NOTE: Keep the stack of clutch plates and clutch discs in the exact order as removed or damage to the component may occur.

Remove the retainer clips from both rear axle disc and plate kits to allow separation of the clutch discs and clutch plates for cleaning and inspection.

Fig 13: Retainer Clips

Courtesy of FORD MOTOR CO.

Inspect the following components.
- The clutch plates and clutch discs for cracks, excessive wear and distortion. Install an entirely new stack of clutch plates and discs on both sides if discarding one or more of the clutch plates or clutch discs.
- The differential pinion shaft and the differential case for excessive wear and pitting.
- The differential side gear and differential pinion gear teeth.