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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 640 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> Disassembly And Assembly >> Differential Case and Ring Gear - Traction-Lok® >> Disassembly

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

WARNING: This page is about a different car, the 2004 Ford Pickup and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the differential case. Refer to DIFFERENTIAL CASE .
    NOTE: When refilling the axle with lubricant, first add 0.163 L (5.5 ounces) of friction modifier.
  2. Match-mark the differential case.
    1. Match-mark the differential case flange (ring gear) and button (cover) halves.
    2. Match-mark the differential pinion shafts and corresponding ramps.
      Fig 1: Identifying Match-Marks
      G02768992Courtesy of FORD MOTOR CO.
    3. NOTE: An axle shaft held in a vise, with the shaft splines extending not more than 3 inches above the vise jaws, makes an excellent holding fixture for the differential case.
    Fig 2: Loosening Differential Case Bolts
    G02768993Courtesy of FORD MOTOR CO.
  3. Loosen, but do not remove the bolts.
  4. Place the differential assembly on a bench.
  5. Remove the bolts and the button half of the differential case.
    Fig 3: Removing Differential Case Bolts
    G02768994Courtesy of FORD MOTOR CO.
  6. Remove the differential side gear, side gear ring, rear axle disc and plate kit, differential pinion gears and the differential pinion shafts. Keep these parts in order for correct installation by placing them aside with the button half of the differential case.
    Fig 4: Identifying Side Gear Ring
    G02768995Courtesy of FORD MOTOR CO.
  7. Remove the side gear ring and the rear axle disc and plate kit from the flange half of the differential case. Keep these parts in order by placing them on the pinion flange as shown.
    Fig 5: Removing Side Gear Ring And Rear Axle Disc And Plate Kit From Flange Half Of Differential Case
    G02768996Courtesy of FORD MOTOR CO.
  8. Inspect the following components:
    • The clutch plates and clutch discs for cracks, excessive wear and distortion. Always install an entirely new rear axle disc and plate kit on both sides if discarding one or more of the clutch plates or clutch discs.
    • The differential pinion shafts and the ramp surfaces on the differential case for excessive wear or pitting.
    • The differential side gear and differential pinion gear teeth.
    • The differential side gear races that bear on the differential side gear rings.
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