Disassembly And Assembly

1. Remove the differential case from the rear axle housing.
2. Remove the differential ring gear.
3. Disassemble the parts in the order indicated in the following illustration and table.
   Fig 1: Exploded View Of Rear Axle Differential Case - Traction-Lok®

   Courtesy of FORD MOTOR CO.
4. To assemble, reverse the disassembly procedure.
5. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
   • If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.
   Fig 2: Checking The Torque Necessary To Rotate One Differential Side Gear

   Courtesy of FORD MOTOR CO.

Item 3: Differential Clutch Spring Disassembly Note 

1. Remove the differential clutch spring.
   Fig 3: Removing Differential Clutch Spring

   Courtesy of FORD MOTOR CO.

Item 6: Differential Pinion Side Gear Disassembly Note 

1. Remove the differential gears.
   1. Remove the two differential pinion gears and pinion thrust washers.
   2. Remove the two differential side gears with the clutch packs and the shims and tag them "left" and "right."
   Fig 4: Removing Differential Gears

   Courtesy of FORD MOTOR CO.

Item 7: Differential Clutch Pack Disassembly Note 

CAUTION: Keep the differential clutch packs in order. Do not mix them. Always reassemble them in the same sequence.
CAUTION: Do not use acids or solvents when cleaning the differential clutch packs. Wipe the components only with a clean, lint-free cloth.
Fig 5: Removing Differential Clutch Packs And Shims
Courtesy of FORD MOTOR CO.
1. Remove the differential clutch packs and shims from the differential side gears.
   • Clean and inspect the differential clutch packs for wear and damage. Clean and inspect the remaining differential components for wear and damage. Install new parts as necessary.

Item 8: Differential Clutch Pack Selective Shim Assembly Note 

CAUTION: Use 118 ml (4 oz.) of additive friction modifier in the axle.
Fig 6: Lubricating Each Steel Clutch
Courtesy of FORD MOTOR CO.
1. Lubricate each steel clutch plate with additive friction modifier and soak all friction plates for no less than 15 minutes.
CAUTION: Do not mix the clutch plates, clutch discs or shims from one side with the other.
Fig 7: Assembling Differential Clutch Packs (Without The Shims)
Courtesy of FORD MOTOR CO.
2. Assemble the differential clutch packs (without the shims) on their respective differential side gear.
3. Place the base portion of the special tool in a vise, then install the differential clutch pack and differential side gear (without the shim).
   Fig 8: Installing Differential Clutch

   Courtesy of FORD MOTOR CO.
4. Position the special tool hand-tight on top of the differential clutch pack.
   Fig 9: Positioning Special Tool On Top Of Differential Clutch Pack

   Courtesy of FORD MOTOR CO.
5. Install the special tool over the disc and differential clutch pack.
   Fig 10: Installing Special Tool Over The Disc And Differential Clutch Pack

   Courtesy of FORD MOTOR CO.
6. Install the nut.
   Fig 11: Installing Nut

   Courtesy of FORD MOTOR CO.
7. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.

   Selective Shims 

   DESCRIPTION CHART
   
   

   Part Number	Description
   E0AZ-4A324-G	0.025 Inch
   E0AZ-4A324-H	0.030 Inch
   E0AZ-4A324-C	0.035 Inch
   E0AZ-4A324-D	0.040 Inch
   E0AZ-4A324-F	0.045 Inch

   Fig 12: Inserting Feeler Gauge Between Differential Clutch Pack

   Courtesy of FORD MOTOR CO.
8. Remove the special tool from the differential clutch pack and differential side gear assembly.
9. Install the shim(s) on the differential clutch pack and differential side gear assembly.

Item 7: Differential Clutch Pack Assembly Note 

1. Install the differential side gear assemblies in the differential case.
   Fig 13: Installing Differential Side Gear Assemblies In Differential Case

   Courtesy of FORD MOTOR CO.

Item 3: Differential Clutch Spring Assembly Note 

1. Using a soft-faced hammer, install the differential clutch spring.
   Fig 14: Installing Differential Clutch Spring

   Courtesy of FORD MOTOR CO.

Item 1: Differential Pinion Shaft Lock Bolt Assembly Note 

1. Install the differential pinion shaft and install a new bolt.
   Fig 15: Installing Differential Pinion Shaft Bolt

   Courtesy of FORD MOTOR CO.