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Home >> Ford >> 2002 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2932 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> Disassembly And Assembly >> Differential Case and Ring Gear - Trac-Lok® >> Disassembly

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

WARNING: This page is about a different car, the 2011 Ford Pickup and 2011 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .
  2. Index-mark the differential case.
    1. Index-mark the differential case halves.
    2. Index-mark the differential pinion shafts and corresponding ramps.
    Fig 1: Identifying Index-Marks On Differential Case Halves And Pininon Shafts
    G06142952Courtesy of FORD MOTOR CO.
  3. Remove and discard 8 of the differential ring gear bolts. Leave 4 differential ring gear bolts loosely assembled, 90 degrees apart.
    Fig 2: Identifying Ring Gear Bolts
    G06776612Courtesy of FORD MOTOR CO.
  4. Tap each differential ring gear bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove and discard the 4 differential ring gear bolts. Remove the differential ring gear.
    Fig 3: Tapping Differential Ring Gear Bolt Head Using Special Tool
    G06776613Courtesy of FORD MOTOR CO.
  5. Loosen, but do not remove, the 8 bolts.
    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 4: Locating Differential Case Bolts
    G06594976Courtesy of FORD MOTOR CO.
  6. Place the differential assembly on a bench.
  7. Remove the bolts and the case top half.
    Fig 5: Locating Differential Case Bolts
    G06594976Courtesy of FORD MOTOR CO.
  8. Remove the differential side gear, 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 top half of the differential case.
    Fig 6: Locating Differential Side Gear
    G06776843Courtesy of FORD MOTOR CO.
  9. Remove the side gear 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 in illustration.
    Fig 7: Locating Rear Axle Disc
    G06776844Courtesy of FORD MOTOR CO.
  10. 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.
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