Differential Case

Disassembly

1. Place case in vise and drive out roll pin that retains the differential pinion shaft (4211) to case.

   
   
   
   
   

2. Remove differential pinion shaft with a drift.

   
   
   
   
   

3. Rotate the differential pinion gears (4215) and differential side gears (4236) until the differential pinion gears turn to the windows of the case. Remove differential pinion gears and differential pinion thrust washers (4230).

4. Lift differential side gears and differential side gear thrust washers (4228) from case.

   
   
   
   
   

Assembly

1. Inspect differential case parts for signs of wear. If wear exists on all parts, replace the entire differential. If one gear shows signs of wear, replace both differential pinion gears and differential side gears as a set.

2. Apply High Temperature 4x4 Axle Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A to differential side gear thrust washers, hub and thrust face of differential side gears. Lubricate differential pinion gears and differential pinion thrust washers with High Temperature 4x4 Axle Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A.

3. Hold differential side gears in place in case with one hand and install differential pinion gears and differential pinion thrust washers with other hand. Rotate the differential side gears and differential pinion gears until the holes in the differential pinion thrust washers and differential pinion gears line up exactly with the holes in the case.

4. Insert the differential pinion shaft in the case. Make sure the hole for the pinion roll pin in the differential pinion shaft lines up with the holes for the roll pin in the case.

5. Insert roll pin. Peen some metal of the case over the roll pin to lock in two places 180 degrees apart. Note the location of the slot in the roll pin. Peen 90 degrees from slot. The torque to turn the differential gears should be less than 3.4 Nm (30 lb-in).