Differential Case and Ring Gear - Traction-Lok: Notes

WARNING: This page is about a different car, the 2012 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOLS

	Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C)
	Gauge, Differential Clutch 205-135 (T80P-4946-A)
	Gauge, Differential Clutch 205-022 (T66L-4204-A)
	Gauge, Differential Clutch (Mandrel for 205-135 [T80P-4946-A]) 205-270 (T87T-4946A)
	Gauge, Differential (Traction-Lock) 205-384 (T97T-4205-A)
	Gauge, Differential (Traction-Lock) 205-386 (T97T-4205-D)
	Installer, Differential Side Bearing 205-010 (T57L-4221-A2)
	Remover, Differential Bearing 205-116 (T77F-4220-B1)
	Rotator, Differential 205-378 (T97T-4205-C)
	Step Plate 205-D016 (D80L-630-5) or equivalent

MATERIAL SPECIFICATIONS

Item	Specification
Additive Friction Modifier XL-3 (US); CXL-3 (Canada)	EST-M2C118-A
Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL (US); CXY-75W140-1L (Canada)	WSL-M2C192-A and GL-5
Premium Long-Life Grease XG-1-C or XG-1-K (US); CXG-1-C (Canada)	ESA-M1C75-B
Threadlock and Sealer TA-25	WSK-M2G351-A5

Fig 1: Exploded View Of Differential Case And Ring Gear - Traction-Lok

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	4204	Differential case
2	4241	Differential pinion shaft lock bolt
3	4236	Differential side gear
4	-	Retainer clip (part of 4880)
5	4230	Differential pinion thrust washer
6	4215	Differential pinion gear
7	-	Plate preload spacer (part of 4880)
8	-	Clutch disc (part of 4880)
9	-	Clutch plate (part of 4880)
10	4211	Differential pinion shaft
11	-	Selective shim (part of 4880)

Initial disassembly

NOTE: If the Diagnostic Chart directed the servicing of the Traction-Lok clutch packs, it is not necessary to remove the differential carrier assembly from the axle housing. Proceed to Step 7.

NOTE: If the differential ring gear backlash between teeth is greater than specification, remove the ring gear to check the differential case flange runout. Do not disassemble the differential carrier assembly.

Remove the differential carrier. Tag the differential shims and bearing cups for location. For additional information, refer to DIFFERENTIAL CARRIER .
Remove and discard the 10 differential ring gear bolts.

Fig 2: Locating Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.

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

Fig 3: Inserting Punch In Differential Ring Gear Bolt Holes

Courtesy of FORD MOTOR CO.

Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.
If checking differential case flange runout, install the bearing cups in their original location and install the differential assembly.
1. Install the bearing caps and differential shims.
  - Rotate the differential assembly to verify the bearings have seated.
2. Install the Dial Indicator Gauge With Holding Fixture and record the differential case runout.
  
  Fig 4: Checking Differential Case Runout
  Courtesy of FORD MOTOR CO.
Final disassembly
Using the Differential Bearing Remover and Step Plate, remove the differential bearings.

Fig 5: Removing Differential Bearings
Courtesy of FORD MOTOR CO.
Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.

Fig 6: Locating Differential Pinion Shaft Lock Bolt And Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Install the Differential Gauge in a suitable vise.

Fig 7: Installing Differential Gauge In Suitable Vise
Courtesy of FORD MOTOR CO.
Install the differential case on the Differential Gauge.

Fig 8: Installing Differential Case On Differential Gauge
Courtesy of FORD MOTOR CO.

NOTE: Apply a small amount of grease to the centering hole of the Differential Gauge.

Fig 9: Installing Differential Gauge Step Plate In Bottom Differential Side Gear

Courtesy of FORD MOTOR CO.

Install the Differential Gauge step plate 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 Differential Gauge step plate.

Fig 10: Installing Differential Gauge 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 11: 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.

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

Fig 12: Inserting Differential Rotator In Pinion Shaft Bore

Courtesy of FORD MOTOR CO.

Insert the Differential Rotator in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential case windows.
Remove the differential pinion gears and differential pinion gear thrust washers.

Fig 13: Locating 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 14: Identifying Differential Side Gears And Differential Clutch Packs
Courtesy of FORD MOTOR CO.

NOTE: Do not use acids or solvents when cleaning the differential clutch pack or damage to the components can result. Wipe components with a clean, lint-free cloth only.

NOTE: When separating the clutch plates and clutch disc, note the sequence in which they are disassembled. They must be reassembled in the same sequence.

Fig 15: Exploded View Of Differential Clutch Disc And Clutch Plates

Courtesy of FORD MOTOR CO.

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