Section 05-02F: Differential, Dana Model 80 Locking Axle
1996 F-350 Super Duty Workshop Manual
DISASSEMBLY AND ASSEMBLY

Differential Case

 

Disassembly

  1.  WARNING: DO NOT UNBOLT CASE HALVES WITHOUT RUNNING A SUITABLE BOLT, WASHERS AND WING NUT LENGTHWISE THROUGH THE CENTER OF THE DIFFERENTIAL ASSEMBLY TO RETAIN THE PRELOADED SPRINGS; OTHERWISE THEY WILL POP LOOSE AND CAUSE POSSIBLE INJURY.

    Remove eight (8) retaining bolts from upper case half.





  1. Lift off upper case half and remove differential (4026) assembly. Assembly should come out as a single unit since it has been bolted together in Step 1.

  1. Remove and inspect case thrust washers.





  1.  CAUTION: The springs are under load and may cause injury if proper precautions are not taken when disassembling the differential assembly.

    Carefully unscrew differential retaining bolt, nut and washers.

  1. Inspect central driver and clutch assemblies for worn teeth. Inspect holdout ring, side gears, springs, thrust blocks, belleville springs and spring retainers for wear or damage.

 

Assembly

  1. NOTE: Make sure to line up the slots in the holdout rings with the long-tooth key in the central driver.

    Assemble differential the same way it came apart. Put assembly in press and compress the springs.





  1. Run the retaining bolt, washers and nut through the assembly and tighten securely. Remove assembly from press.





  1. Install thrust washer in lower case half. Make sure oil groove in thrust washer is visible.





  1. Place differential assembly in lower case half.





  1. Reinstall thrust washer in upper case half, making sure that oil groove on thrust washer is visible. Install upper case half on lower case half.









  1. Install eight (8) bolts and tighten to 103-108 Nm (76-80 lb-ft).





  1. Remove differential retaining bolt, washers and wing nut.