Differential Carrier - Vehicles With: Limited-Slip Differential: Disassembly

WARNING: This page is about a different car, the 2024 Ford Transit-350 HD, 2024 Ford Transit-350, 2024 Ford Transit-250, and 2024 Ford Transit-150. However, it is still accessible from the selected car via links, so may be relevant.

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. Refer to: Differential Carrier
NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential.

Using the general equipment, remove and discard the differential bearings. Use Special Service Tool: 205-D072 (D97L-4221-A) 2 Jaw Puller, 205-D061 (D83T-4205-C2) Step Plate.

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Remove and discard the ring gear bolts.

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

Using the general equipments, remove the ring gear. Use the General Equipment: Punch. Use the General Equipment: Copper Hammer

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If checking differential case flange runout, install the bearing cups in their original location and install the differential assembly.
- Install the bearing caps and differential shims.
- Rotate the differential assembly to verify the bearings have seated.
- Install the Dial Indicator Gauge with Holding Fixture and record the differential case runout. Use Special Service Tool: 308-021 (T75L-4201-A) Gauge, Clutch Housing. Use the General Equipment: Dial Indicator
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NOTE: The differential flange and ring gear flange must be free of any old retaining compound material. Make sure both surfaces are clean and free of oil, dust and debris. Failure to clean the surfaces can result in ring gear runout concerns.

NOTE: Use solvent and Scotch-Brite® pads to remove.

Clean all traces of the old retaining compound material from the differential flange.

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Remove the differential pinion shaft lock bolt.

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Remove the differential pinion shaft.

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Install the Differential Gauge in a suitable vise. Use Special Service Tool: 205-384 (T97T-4205-A) Gauge, Differential (Traction Lock). Use the General Equipment: Vise

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Install the differential case on the Differential Gauge. Use Special Service Tool: 205-384 (T97T-4205-A) Gauge, Differential (Traction Lock). Use the General Equipment: Vise

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

NOTE: Do not over tighten the special tool.

Install the special tool in the bottom differential side gear. Compress the differential side gear. Tighten the hex-head screw until contact is made with the Differential Gauge step plate. Use Special Service Tool: 205-386 (T97T-4205-D) Gauge, Differential (Traction Lock).

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

Rotate and remove the differential pinion gears and differential pinion gear thrust washers.

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NOTE: Do not use acids or solvents when cleaning the differential clutch pack or damage to the components can result. Wipe components with 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.

Remove the differential side gears, the differential side gear thrust washers and the differential side gear clutch packs.

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