Join Date: Apr 1999
Location: Midland County,TX, USA
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Not my area of expertise. But from what little I know about differentials, I wouldn't even think of working on one without all the special tools. Maybe you could use shadetree mechanic procedures to replace the diff rotator bar, but those gauges and fittings I'd insist on.
Sorry, but the editor on TheDieselStop won't allow me to paste illustrations - only text. But here are the words from the workshop manual:
2002 F-Super Duty/Excursion Workshop Manual
SECTION 205-02D: Rear Drive Axle/Differential — Ford 10.50-Inch Ring Gear
DISASSEMBLY AND ASSEMBLY
Differential Case and Ring Gear —One-Piece, Traction-Lok
Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent
Rotator, Differential 205-246 (T86T-4205-A)
Rotator, Limited Slip Differential 205-DS059 (D83T-4205-C) or equivalent
Step Plate 205-D019 (D80L-630-8) or equivalent
Gauge, Differential Clutch 205-135 (T80P-4946-A)
Gauge, Differential (Traction-Lok) 205-380 (T97T-4946-B)
Preload Gauge, Differential Clutch 205-446
Preload Gauge, Differential Clutch 205-447
1. Remove the differential case (4204); for additional information, refer to Differential Case in this section.
2. NOTE: The differential bearings (4221) need not be removed to overhaul the Ford limited slip differential. If bearing removal is required; for additional information, refer to Differential Case in this section.
NOTE: The anti-lock speed sensor ring cannot be reused once removed.
Remove the differential pinion shaft lock bolt, and remove the differential pinion shaft (4211).
• If required, remove the ring gear and anti-lock speed sensor ring.
3. NOTE: This tool does not have the 1/2-inch drive hole.
Install the special tool 205-447 in a suitable vise
4. Install the differential case on the tool.
5. Install the special tool 205-135 in the bottom side gear bore.
• Apply a small amount of grease to the centering hole of the special tool.
6. Install the nut in the upper differential side gear (4236). Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Step Plate.
7. 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 (4215). The dowel bar is used to keep the nut from turning when the forcing screw is tightened.
8. 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 and so must be removed simultaneously with the differential pinion gears.
Insert the special tool 205-246 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.
9. Remove the differential pinion gears and differential pinion thrust washers.
10. Remove the differential side gears and differential clutch packs (4947), and tag them RIGHT and LEFT with the shim.
11. 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 in the Description and Operation portion of this section.
1. Prelubricate each steel clutch plate and soak all friction plates in 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. Clamp the bolt head of the special tool 205-380 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 special tool 205-135 on top of the differential clutch pack.
5. Install the special tool 205-135 over the disc and differential clutch pack.
6. Install the nut of the gauge over the top and base stud. 60 lb/in torque
7. Use the Feeler Gauge Set 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 special tools.
Part Number Description
F75Z-4A324-DA 0.030 Inch
F75Z-4A324-EA 0.035 Inch
F75Z-4A324-FA 0.040 Inch
F75Z-4A324-GA 0.045 Inch
F75Z-4A324-HA 0.050 Inch
F75Z-4A324-JA 0.055 Inch
F75Z-4A324-KA 0.060 Inch
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 in the Description and Operation portion of this section.
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 forcing screw, nut and Step Plate to the differential case.
1. Position the Step Plate in the bottom side gear bore.
2. Position the nut in the top side gear bore and hold it in place.
3. Install the hex-head screw and tighten it two turns after it contacts the bottom Step Plate.
11. NOTE: Prelubricate both sides of the differential pinion thrust washers with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-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: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.
Insert the special tool 205-246 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. CAUTION: If a new pinion shaft lock bolt is not available, use Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 and tighten to specification.
Loosen the forcing screw, and remove the Step Plate and nut from the side gear bores. Install the differential pinion shaft in the differential case.
• Install a new differential pinion shaft lock bolt. 23 lb/ft
14. Replace the differential bearings, if removed.
15. Check the torque required to rotate one differential side gear.
• Install the special tool 205-446 with the (1/2-inch drive hole) as shown.
• The initial break-away torque, if original clutch plates are used, must be within specification. 20 lb/ft. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.
16. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts. 100-120 lb/ft
17. Install the differential case; for additional information, refer to Differential Case in this section.
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My Sierra Blanca in the sig pic was a great pickup for 11.5 years. I sold it a coupla years ago. I drove a hand-me-down 2003 F-150 SuperCrew 4.6L 2V for a while, but it was unacceptable for towing more than a rowboat. Replacement is a 2012 F-150 EcoBoost SuperCrew Lariat that tows my 5,000-pound TT like a dream.
Last edited by SmokeyWren; 06-10-2010 at 01:56 PM.