Differential Case and Ring Gear - One-Piece, Traction-Lok®: Disassembly

WARNING: This page is about a different car, the 2009 Ford Pickup and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the differential carrier. For additional information, refer to Differential Carrier .
Remove and discard the 12 ring gear bolts.

Fig 1: Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Insert a punch and drive off the ring gear.

Fig 2: Driving Off Ring Gear

Courtesy of FORD MOTOR CO.

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

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

If required, remove the anti-lock speed sensor ring.
Remove and discard the differential pinion shaft lock bolt.

Fig 3: Differential Pinion Shaft Lock Bolt

Courtesy of FORD MOTOR CO.

Remove the differential pinion shaft.

Fig 4: Differential Pinion Shaft

Courtesy of FORD MOTOR CO.

Install the Differential Clutch Preload Gauge in a suitable vise.

Fig 5: Identifying Special Tool (205-447) In A Vise

Courtesy of FORD MOTOR CO.

Install the differential case on the Differential Clutch Preload Gauge.

Fig 6: Installing Differential Case On Differential Clutch Preload Gauge

Courtesy of FORD MOTOR CO.

NOTE: Apply a small amount of grease to the centering hole of the Limited Slip Differential Rotator.

Install the Limited Slip Differential Rotator in the bottom side gear bore.

Fig 7: Identifying Special Tool (205-DS059) In Bottom Side Gear Bore

Courtesy of FORD MOTOR CO.

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 Step Plate.

Fig 8: Identifying Special Tool (205-DS059) In Differential Case

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 gear away from the differential pinion gears. The dowel bar is used to keep the nut from turning when the forcing screw is tightened.

Fig 9: Dowel Bar In Hole Of Nut

Courtesy of FORD MOTOR CO.

NOTE: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool.

NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears.

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

Fig 10: Identifying Special Tool (205-246) In Pinion Shaft Bore

Courtesy of FORD MOTOR CO.

Remove the differential pinion gears and differential pinion thrust washers.

Fig 11: Differential Pinion Gears & Differential Pinion Thrust Washers

Courtesy of FORD MOTOR CO.

Remove the differential side gears and differential clutch packs with the shims and tag them RH and LH.

Fig 12: Differential Clutch Pack

Courtesy of FORD MOTOR CO.

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

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

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

Fig 13: Exploded View Of Differential Side Gears, Clutch Plates & Clutch Discs

Courtesy of FORD MOTOR CO.