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

CAUTION: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the axle.

Lubricate each steel clutch plate and soak all friction plates for no less than 15 minutes.
- Use Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification ESTM2C118-A
  
  Fig 1: Locating Steel Clutch Plate
  Courtesy of FORD MOTOR CO.

CAUTION: Do not mix the differential clutch packs or shims from one side with the other.

Fig 2: Assembling Differential Clutch Packs (Without Shims) On Differential Side Gears

Courtesy of FORD MOTOR CO.

Assemble the differential clutch packs (without the shims) on their respective differential side gears.
Place the base portion of the special tool in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool.

Fig 3: Installing Differential Side Gear And Differential Clutch Pack (Without Shim) On Tool
Courtesy of FORD MOTOR CO.
Position the special tool hand-tight on top of the differential clutch pack.

Fig 4: Positioning Special Tool On Top Of Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the special tool over the disc and differential clutch pack.

Fig 5: Installing Special Tool Over Disc And Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the nut.

Fig 6: Installing Nut
Courtesy of FORD MOTOR CO.

NOTE: Clutch Pack Rebuild Kit F5AZ-4947-A is available for this application.

Fig 7: Inserting Thickest Feeler Gauge Blade Between Tool And Differential Clutch Pack

Courtesy of FORD MOTOR CO.

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 REFERENCE

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

Remove the special tools from the differential clutch pack and differential side gear assembly.
Install shim(s) on the differential clutch pack and differential side gear assembly.
Install the differential side gear assemblies in the differential case.

Fig 8: Installing Differential Side Gear Assemblies In Differential Case
Courtesy of FORD MOTOR CO.
Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case.

Fig 9: Installing Differential Pinion Gear And Thrust Washer Assemblies In Differential Case
Courtesy of FORD MOTOR CO.
Using a soft-faced hammer, install the differential clutch spring.

Fig 10: Installing Differential Clutch Spring
Courtesy of FORD MOTOR CO.
Install the differential pinion shaft and install a new bolt finger-tight.

Fig 11: Installing Differential Pinion Shaft And Bolt
Courtesy of FORD MOTOR CO.
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 12: Identifying Differential Side Gear Rotating Torque
  Courtesy of FORD MOTOR CO.
Using the special tool, install the differential bearings, if removed.

Fig 13: Installing Differential Bearings
Courtesy of FORD MOTOR CO.
Position the differential ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.

Fig 14: Installing Differential Ring Gear On Differential Case
Courtesy of FORD MOTOR CO.
Install the bolts.
- Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSKM2G349-A1 to the bolt threads.
  
  Fig 15: Identifying Differential Case Bolt Tightening Torque
  Courtesy of FORD MOTOR CO.
Install the differential assembly in the differential housing. For additional information, refer to DIFFERENTIAL CASE .