Differential Case, Limited Slip, Ford Design

Ford Design Limited Slip Differential

Disassembly

1. NOTE: The differential bearings (4221) need not be removed to overhaul the differential. If bearing removal is required, refer to Differential Bearings in this section.

   Remove the differential pinion shaft lock bolt, and remove the differential pinion shaft (4211)

   

2. Install the Limited Slip Tool D83T-4205-A or equivalent in a suitable vise.

   

3. Position the differential case on the tool.

   

4. Install the Step Plate Adapter D80L-630-8 or equivalent in the bottom side gear bore. Apply a small amount of grease to the centering hole of the Step Plate Adapter.

   

5. Install the Limited Slip Rotating Tool Nut D83T-4205-C or equivalent in the upper differential side gear (4236). Hold the Nut in position while installing the Limited Slip Rotating Tool Forcing Screw D83T-4205-C or equivalent. Tighten the hex-head screw until contact is made with the Step Plate Adapter D80L-630-8 or equivalent.

   

6. Insert a suitable dowel bar in the hole of the Limited Slip Rotating Tool Nut D83T-4205-C or equivalent. Tighten the Limited Slip Rotating Tool Forcing Screw D83T-4205-C or equivalent to force the differential side gear away from the differential pinion gears (4215). The dowel bar is used to keep the Nut from turning when the Forcing Screw is tightened.

   

7.  WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING THE DIFFERENTIAL CASE WITH THE DIFFERENTIAL ROTATING TOOL.

   NOTE: Differential pinion thrust washers (4230) cannot be removed independently of the differential pinion gears. They must be removed simultaneously with the differential pinion gears.

   Insert the Limited Slip Differential Rotating Tool T86T-4205-A 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.

   

8. Remove the differential pinion gears and differential pinion thrust washers.

   

9. Remove the differential side gears and differential clutch packs (4947), and tag them RIGHT and LEFT with the shim.

   

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

     CAUTION: 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. Refer to the disassembled view of the limited slip differential case at the beginning of this procedure.

    

Assembly

1. Prelubricate each steel clutch plate and soak all friction plates with 236.5 ml (8 ounces) Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.

   

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

   NOTE: The Belleville spring is a dished plate.

   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 T97T-4946-B for the procedure.

   Clamp the bolt head of the Traction-Lok® Clutch Gauge Mandrel T97T-4946-B in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.

   

4. Position the Traction-Lok® Clutch Gauge Disc T80P-4946-A on top of the differential clutch pack.

   

5. Install the Traction-Lok® Clutch Gauge T80P-4946-A over the Disc and differential clutch pack.

   

6. Install the nut of the gauge over the top and base stud. Tighten the nut to 6.7 Nm (60 lb-in).

   

7. Use the Feeler Gauge D81L-4201-A or equivalent 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 tools.

   

8. Place the shim and Belleville spring on the differential clutch pack.

   • The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case.
   • Refer to the exploded view at the beginning of this procedure.

   

9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case.

   • Hold the upper differential clutch pack and side gear assembly in place to prevent it from falling out of the differential case.

   

10. NOTE: Apply a small amount of grease to the step plate bore.

    NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.

    Assemble the Limited Slip Rotating Tool Forcing Screw and Nut D83T-4205-C and Step Plate Adapter D80L-630-8 or equivalents to the differential case.

    1. Position the Step Plate Adapter D80L-630-8 or equivalent in the bottom side gear bore.
    2. Position the Limited Slip Rotating Tool Nut D83T-4205-C or equivalent in the top side gear bore and hold it in place.
    3. Install the Limited Slip Rotating Tool Forcing Screw D83T-4205-C or equivalent and tighten it two turns after it contacts the Limited Slip Rotating Tool Step Place Adapter D80L-630-8 or equivalent.

    

11. NOTE: Prelubricate both sides of the differential pinion thrust washers with Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

    NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.

    Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth.

    

12.  WARNING: KEEP FINGERS/HANDS AWAY FROM PINION GEARS WHEN ROTATING THE DIFFERENTIAL CASE WITH THE DIFFERENTIAL ROTATING TOOL.

    NOTE: If will probably be necessary to loosen or tighten the Limited Slip Rotating Tool Forcing Screw D83T-4205-C or equivalent to allow the differential pinion gears and differential side gears to rotate.

    Insert the Limited Slip Differential Rotating Tool T86T-4205-A into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears.

    

13. Loosen the Limited Slip Rotating Tool Forcing Screw D83T-4205-C or equivalent, and remove the tools. Install the differential pinion shaft in the differential case.

    Install a new differential pinion shaft lock bolt or apply Threadlock® and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G315-A5 (Type II) to the used lock bolt threads. Tighten the differential pinion shaft lock bolt to 20-40 Nm (15-30 lb-ft).