Differential Case and Ring Gear - Traction-Lok®: Disassembly

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the differential case (4204). For additional information, refer to DIFFERENTIAL CASE .

NOTE: The differential bearings (4221) need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the 2-Jaw Puller.

NOTE: The anti-lock speed sensor ring cannot be reused once removed

Fig 1: Removing Differential Pinion Shaft Lock Bolt

Courtesy of FORD MOTOR CO.

Remove the differential pinion shaft lock bolt and remove the differential pinion shaft (4211).
- If required, remove the ring gear and anti-lock speed sensor ring.
Install the special tool in a suitable vise.

Fig 2: Installing Special Tool In Suitable Vise
Courtesy of FORD MOTOR CO.
Install the differential case on the tool.

Fig 3: Installing Differential Case On Tool
Courtesy of FORD MOTOR CO.

NOTE: Apply a small amount of grease to the centering hole of the special tool.

Fig 4: Installing Special Tool In Bottom Side Gear Bore

Courtesy of FORD MOTOR CO.

Install the special tool in the bottom side gear bore.
Install the nut in the upper differential side gear (4236). Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Step Plate.

Fig 5: Installing Nut In Upper Differential Side Gear
Courtesy of FORD MOTOR CO.

NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened.

Fig 6: Tightening Forcing Screw To Force Differential Side Gear Away From Differential Pinion Gears (4215)

Courtesy of FORD MOTOR CO.

Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears (4215).

WARNING: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool.

NOTE: Differential pinion thrust washers (4230) cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears.

Fig 7: Inserting Special Tool In Pinion Shaft Bore And Turning Differential Case

Courtesy of FORD MOTOR CO.

Insert the special tool in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential pinion thrust washers out to the differential case windows.
Remove the differential pinion gears and differential pinion thrust washers.

Fig 8: Removing Differential Pinion Gears And Differential Pinion Thrust Washers
Courtesy of FORD MOTOR CO.
Remove the differential side gears and differential clutch packs (4947), and tag them RIGHT and LEFT with the shim.

Fig 9: Removing Differential Side Gears And Differential Clutch Packs
Courtesy of FORD MOTOR CO.

CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence.

CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only.

Separate the differential clutch discs and clutch plates for cleaning and inspection. Refer to the disassembled view of the limited slip differential case in the DESCRIPTION AND OPERATION portion of this article.

Fig 10: Separating Differential Clutch Discs And Clutch Plates

Courtesy of FORD MOTOR CO.