Clutch Pack Preload Adjustment

1.  WARNING: DUE TO THE SPRING TENSION, CARE MUST BE USED WHEN REMOVING THE DIFFERENTIAL CLUTCH SPRING (4214).

   NOTE: Before preload can be adjusted, the axle shafts (4234) must be removed following the procedure in Section 05-02G. The axle shafts must be removed completely from the axle housing so that the oil seals will not be damaged. After preload adjustment, install the axle shaft following the procedure in Section 05-02G.

   With a suitable drift, drive the differential clutch spring halfway out of the differential case (4204). Rotate the differential case 180 degrees. Hold the differential clutch spring with a pair of pliers and tap the differential clutch spring until it is removed from the differential case.

   

2. NOTE: A 304.8mm (12-inch) extension is required to remove the differential pinion gears (4215).

   Using Gear Rotator T80P-4205-A rotate the pinion gears until they can be removed from the differential case.

   

3. NOTE: Do not mix differential clutch packs (4947) or rear axle differential clutch shims (4A324) from one side with the other.

   Remove the right and left differential side gears (4236) and differential clutch pack with the shim and tag them "right" and "left." Set them aside. Clean and inspect the remaining parts of the differential case assembly for wear or damage. Replace parts as required.

   

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

   Clean and inspect the differential clutch packs for wear and replace parts as necessary.

   

5.  CAUTION: Prelubricate all friction clutch plates with Ford Friction Modifier F3TZ-19B546-MA or equivalent meeting Ford specification WSP-M2C196-A by soaking the plates for 15 minutes prior to assembly.

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

   Assemble the differential clutch packs (without rear axle differential clutch shims) on the respective differential side gears.

   

6. Place the base portion of Traction-Lok® Clutch Gauge T87T-4946-A in a vise. Install the differential clutch pack and differential side gear (without the rear axle differential clutch shim) over the base.

   

7. Install the disc of Traction-Lok® Clutch Gauge T80P-4946-A over the base and on top of the differential clutch pack.

   

8. Install the top portion of the gauge over the disc and base stud.

   

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

   

10. Using Feeler Gauge D81L-4201-A or equivalent, select the thickest blade that will enter between the tool and the differential clutch pack. This reading will be the thickness of the new rear axle differential clutch shim.

    

11.  CAUTION: Prelubricate friction clutch plates with Ford Friction Modifier F3TZ-19B546-MA or equivalent meeting Ford specification WSP-M2C196-A by soaking the plates for 15 minutes prior to reassembly.

    Install the differential side gear, differential clutch pack and new rear axle differential clutch shim into the cavity in the differential case. Repeat these procedures for the other side.

    

12. NOTE: A 304.8mm (12-inch) extension is required to install the differential pinion gears.

    Place the differential pinion gears and differential pinion thrust washers (4230) 180 degrees apart on the differential side gears. Install Gear Rotator T80P-4205-A as shown.

    

13. Rotate the tool until the differential pinion gears are aligned with the pinion shaft hole as shown. Remove the tool from the differential case.

    

14. NOTE: Inspect the differential clutch spring for damage.

    Hold the differential clutch spring up to the differential case window and, with a soft-faced hammer, hammer the differential clutch spring into position.