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

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Remove the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .
Remove the 12 differential ring gear bolts.

Fig 1: Removing 12 Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Care should be taken not to damage the differential ring gear bolt hole threads.

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

Fig 2: Inserting Punch In Differential Ring Gear Bolt Holes

Courtesy of FORD MOTOR CO.

Insert a punch in the differential ring gear bolt holes. Drive off the differential ring gear and, if necessary, the anti-lock ring.

NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential.

Fig 3: Using Special Tools To Remove Differential Bearings

Courtesy of FORD MOTOR CO.

If necessary, use the special tools to remove the differential bearings.
Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.

Fig 4: Removing Differential Pinion Shaft Lock Bolt And Removing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Install the special tool in a suitable vise.

Fig 5: Installing Special Tool (205-384) In Suitable Vise
Courtesy of FORD MOTOR CO.
Install the differential case on the special tool.

Fig 6: Installing Differential Case On Special Tool
Courtesy of FORD MOTOR CO.

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

Fig 7: Installing Special Tool In Bottom Differential Side Gear (205-386)

Courtesy of FORD MOTOR CO.

Install the special tool in the bottom differential side gear.
Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the step plate.

Fig 8: 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 9: Inserting Suitable Dowel Bar In Hole Of Nut

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 gears away from the differential pinion gears.

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

NOTE: Differential pinion gear thrust washers cannot be removed independently of the differential pinion gears.

Fig 10: Inserting Special Tool (205-378) 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 gear thrust washers out to the differential case windows.
Remove the differential pinion gears and differential pinion gear thrust washers.

Fig 11: Removing Differential Pinion Gears And Differential Pinion Gear Thrust Washers
Courtesy of FORD MOTOR CO.
Remove the differential side gears and differential clutch packs with the selective shim and Belleville spring, tag them RH and LH.

Fig 12: Removing Differential Clutch Packs With Selective Shim And Belleville Spring
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.

Fig 13: Separating Differential Clutch Discs And Clutch Plates For Cleaning And Inspection

Courtesy of FORD MOTOR CO.

Separate the differential clutch discs and clutch plates for cleaning and inspection.