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

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 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 21 C.L. (7 ounces) 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.

Fig 1: Removing Differential Ring Gear

Courtesy of FORD MOTOR CO.

If necessary, remove the differential ring gear.

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

Fig 2: Removing Differential Pinion Shaft Lock Pin

Courtesy of FORD MOTOR CO.

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

Fig 3: Removing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Position the special tool in the bottom differential side gear bore.
- Apply a small amount of grease to the special tool's centering hole.
Fig 4: Positioning Special Tool In Bottom Differential Side Gear Bore
Courtesy of FORD MOTOR CO.
Screw the special tool into the Step Plate.

Fig 5: Screwing Special Tool Into Step Plate
Courtesy of FORD MOTOR CO.

CAUTION: Do not overtighten the special tool. Overtightening can damage the rear axle disc and plate kit.

Fig 6: Tightening Special Tool

Courtesy of FORD MOTOR CO.

Tighten the special tool enough to move the differential side gears away from the differential pinion gears and relieve the normal loaded condition.
Using a 0.762-mm (0.030-inch) thick piece of shim or gauge stock, push the differential pinion thrust washers out from behind the differential pinion gears, and remove them.

Fig 7: Pushing Differential Pinion Thrust Washers Out From Behind Differential Pinion Gears
Courtesy of FORD MOTOR CO.

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

Fig 8: Loosening Special Tool

Courtesy of FORD MOTOR CO.

Loosen the special tool.

NOTE: When attempting to rotate the differential side gears, tighten or loosen the special tool as necessary to permit gear movement.

Fig 9: Tightening Special Tool

Courtesy of FORD MOTOR CO.

Tighten the special tool until the differential pinion gears move slightly.
Insert the special tool 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 10: Inserting Special Tool Into Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Hold the top differential side gear and rear axle disc and plate kit in the differential case, and remove the special tool.

Fig 11: Holding Top Differential Side Gear And Rear Axle Disc And Plate Kit In Differential Case
Courtesy of FORD MOTOR CO.
Continue to hold the differential side gear and the rear axle disc and plate kit, and remove the special tool.

Fig 12: Continuing To Hold Differential Side Gear And Rear Axle Disc And Plate Kit
Courtesy of FORD MOTOR CO.
Remove the top differential side gear and the rear axle disc and plate kit.

Fig 13: Removing Top Differential Side Gear And Rear Axle Disc And Plate Kit
Courtesy of FORD MOTOR CO.
Turn the differential case so that the flange or differential ring gear side is facing upward. Ease the special tool, differential side gear and rear axle disc and plate kit out of the differential case.

CAUTION: Keep the stack of clutch plates and clutch discs in the exact order as removed.

Fig 14: Removing Retainer Clips From Both Rear Axle Disc And Plate Kits

Courtesy of FORD MOTOR CO.

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.
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.