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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 238 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- Excursion & F250-F350 Super Duty) >> Disassembly And Assembly >> Differential Case and Ring Gear - Two-Piece, Traction-Lok >> Assembly

Differential Case and Ring Gear - Two-Piece, Traction-Lok: Assembly

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Prelubricate each clutch disc and soak the clutch friction plate for at least 15 minutes in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.
    Fig 1: Prelubricating Each Clutch Disc
    G01551360Courtesy of FORD MOTOR CO.
    2. CAUTION: Do not mix the differential clutch packs or shims from one side with the other.
    NOTE: The Belleville spring is a dished plate.
    Fig 2: Assembling Differential Clutch Packs (Without Shims And Belleville Springs)
    G01551361Courtesy of FORD MOTOR CO.
  2. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.
    3. NOTE: Use the Traction-Lok Clutch Gauge Mandrel for the procedure. Refer to the Special Tool(s)  Chart.
  3. Clamp the bolt head of the Traction-Lok Clutch Gauge in a vise.
    • Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.
      Fig 3: Installing Differential Clutch Pack And Differential Side Gear (Without Shim Or Belleville Spring) On Gauge
      G01551362Courtesy of FORD MOTOR CO.
  4. Position the Traction-Lok Clutch Gauge disc on top of the differential clutch pack.
    Fig 4: Positioning Traction-Lok Clutch Gauge Disc On Top Of Differential Clutch Pack
    G01551363Courtesy of FORD MOTOR CO.
  5. Install the Traction-Lok Clutch Gauge housing over the disc and tighten the nut.
    Fig 5: Installing Traction-Lok Clutch Gauge Housing Over Disc
    G01551364Courtesy of FORD MOTOR CO.
  6. Use a feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack.
    • The reading will be the thickness of the new clutch shim.
    • Select the correct shim size, and remove the Traction-Lok Clutch Gauge.
      Fig 6: Removing Traction-Lok Clutch Gauge
      G01551365Courtesy of FORD MOTOR CO.
  7. Place the selected shim and Belleville spring on the differential clutch pack.
    • The dished or concave side of the Belleville spring must be face up and against the thrust face of the differential case.
      Fig 7: Placing Selected Shim And Belleville Spring On Differential Clutch Pack
      G01551366Courtesy of FORD MOTOR CO.
  8. Install the differential side gear and differential clutch pack into the left case half (ring gear side).
    Fig 8: Installing Differential Side Gear And Differential Clutch Pack Into Left Case Half (Ring Gear Side)
    G01551367Courtesy of FORD MOTOR CO.
  9. Position left differential case half on the Traction-Lok Torque Tool Set.
    Fig 9: Positioning left differential case half on Traction-Lok Torque Tool Set
    G01551368Courtesy of FORD MOTOR CO.
  10. Lubricate the differential pinion gears, pinion gear thrust washers and the differential pinion shaft with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
    • Install the differential pinion gears in the differential pinion shaft.
      Fig 10: Lubricating Differential Pinion Gears, Pinion Gear Thrust Washers And Differential Pinion Shaft With Premium Long-Life Grease Xg-1-C
      G01551369Courtesy of FORD MOTOR CO.
  11. Install the differential pinion shaft and the differential pinion gears.
    Fig 11: Installing Differential Pinion Shaft And Differential Pinion Gears
    G01551370Courtesy of FORD MOTOR CO.
  12. Install the right differential clutch pack and differential side gear into the right case half.
    Fig 12: Installing Right Differential Clutch Pack And Differential Side Gear Into Right Case Half
    G01551371Courtesy of FORD MOTOR CO.
  13. Position the right differential case half with the index marks aligned.
    Fig 13: Positioning Right Differential Case Half With Index Marks Aligned
    G01551372Courtesy of FORD MOTOR CO.
  14. Install the retaining bolts and tighten.
    Fig 14: Installing Retaining Bolts And Tighten
    G01551373Courtesy of FORD MOTOR CO.
  15. Check the torque required to rotate one differential side gear.
    • Install the Traction-Lok Torque Tool Set with the 1/2-inch drive hole as shown.
    • The initial break-away torque, if the original clutch plates are used, must be within specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.
      Fig 15: Checking Torque Required To Rotate One Differential Side Gear
      G01551374Courtesy of FORD MOTOR CO.
  16. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts.
    Fig 16: Installing Ring Gear
    G01551375Courtesy of FORD MOTOR CO.
    Fig 17: Tightening Retaining Bolts Anti-Lock Speed Sensor Ring On Differential Case
    G01551376Courtesy of FORD MOTOR CO.
  17. Install the differential case. Refer to Differential Case .
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