10.5 STERLING REAR DIFF CLUTCH PACK - Diesel Forum - TheDieselStop.com
Ford Diesel Forum / Powerstroke Forum
Ford Diesel Forum / Powerstroke Forum
Go Back   Diesel Forum - TheDieselStop.com > 1999-2007 Ford Super Duties > 99 & up 7.3L Power Stroke Engine and Drivetrain

99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the 99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

TheDieselstop.com is the premier Diesel Truck Forum on the internet. Registered Users do not see the above ads.
Reply
 
LinkBack Thread Tools Display Modes
Old 06-10-2010, 10:05 AM   #1 (permalink)
Junior Member
 
Join Date: Jun 2010
Location: HIGGANUM, CT
Posts: 4
My Photos: (0)
Feedback Score: 0 reviews
10.5 STERLING REAR DIFF CLUTCH PACK

I am new to the site and think there is a ton of info. Just wondering if there are any special tools absolutley required to change the clutch pack in my 2002 F-350 PS crew cab with 3.73 sterling 10.5 LS rear diff?
sgreco410 is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 06-10-2010, 12:54 PM   #2 (permalink)
Lifetime Supporting Member
 
SmokeyWren's Avatar
 
Join Date: Apr 1999
Location: Midland County,TX, USA
Posts: 18,788
My Photos: (44)
Feedback Score: 0 reviews
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

Special Tool(s)
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

Disassembly

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.

Assembly

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.
__________________

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 12:56 PM.
SmokeyWren is offline   Reply With Quote Quick reply to this message
Old 06-10-2010, 01:58 PM   #3 (permalink)
Junior Member
 
Join Date: Jun 2010
Location: HIGGANUM, CT
Posts: 4
My Photos: (0)
Feedback Score: 0 reviews
Smokey, Thanks a bunch! I picked up clutch kit today and it does have instructoions with special tools. I am investigating to understand better. Does not seem that complicated. Bit you never know.
Thanks

Last edited by klhansen; 06-10-2010 at 08:26 PM. Reason: removed quoted stuff - long
sgreco410 is offline   Reply With Quote Quick reply to this message
Old 06-10-2010, 03:05 PM   #4 (permalink)
Lifetime Supporting Member
Lifetime Supporting Member
 
Join Date: Mar 2010
Location: St Pete, FL
Posts: 597
My Photos: (0)
Feedback Score: 0 reviews
Where did you pick up the clutch pack and how much did it set you back?

I need to redo mine because I dont think they have every been changed in 250k miles and I have the embarrassing '1 wheel peel' on pavement. Also offroad when stuck in the mud half the time its like an open.
__________________
2000 F350 7.3l auto 4x4 CCLB Dually lariat, my new baby purchased 8-22-11 . 66/74/1.15 S300 turbo, TS chip from swamps (daily with 60 tune), proper gauges, coolant filter w/ ELC, 19.5s.

2006 E350 6.0 auto cutaway van XLT with fiberglass roadside assistance box w/ air compressor. Company owned but mods will come.

AutoEnginuity w/ Ford Enhanced - Tampa Bay area, FL. Just buy me dinner + fuel
Demoh is offline   Reply With Quote Quick reply to this message
Old 06-10-2010, 03:38 PM   #5 (permalink)
Senior Member
 
Join Date: Jan 2003
Location: Dundee, IL
Posts: 2,699
My Photos: (19)
Feedback Score: 0 reviews
My stock LS was like that as I left the dealer lot brand new... PowerLock or a Detroit. That's about all I'd go with.
__________________
'02 F-350 "Babe The Big Blue Truck" 4x4, Ext. Cab, 8' bed, SRW

DP-Tuner 80T, 160cc single shots, GTP38R turbo, Ceramic coated IH up-pipes, coolant filter, 6637, DIY exhaust brake, openair CCV, propane, SBC DD all ceramic clutch, ISSPRO EV boost/pyro/HPOP pres./rear end temp, 4" lift, traction bars, 255/70R22.5 tires, York air compressor, 16 flashy lights, 12 strobes, 12 switches on console, 9 switches on the dash, 7 two-way radios, 5 air horns, laptop, siren, 105 gal. in-bed fuel tank, Kennesaw Mountain front bumper

'86 H-D Sportster - 16" apes, custom paint, custom pipes to fishtails, single fire ignition, leather saddle bags on custom brackets, bagger fender, solo seat, home made luggage rack, all LED rear lights

'66 Bronco "Big Little Monster"
BTBBT is offline   Reply With Quote Quick reply to this message
Old 06-11-2010, 11:37 AM   #6 (permalink)
Lifetime Supporting Member
Lifetime Supporting Member
 
Join Date: Mar 2010
Location: St Pete, FL
Posts: 597
My Photos: (0)
Feedback Score: 0 reviews
Quote:
Originally Posted by BTBBT View Post
My stock LS was like that as I left the dealer lot brand new... PowerLock or a Detroit. That's about all I'd go with.
Ill get a real locker when (if) I re-gear both diffs, but until then I just wanted to throw new clutches in. In my vic's 8.8 I swapped over to a much heavier spring from an f150 with the existing clutches and now that diff performs nicely. Is there anything I can do for the sterling like that?
__________________
2000 F350 7.3l auto 4x4 CCLB Dually lariat, my new baby purchased 8-22-11 . 66/74/1.15 S300 turbo, TS chip from swamps (daily with 60 tune), proper gauges, coolant filter w/ ELC, 19.5s.

2006 E350 6.0 auto cutaway van XLT with fiberglass roadside assistance box w/ air compressor. Company owned but mods will come.

AutoEnginuity w/ Ford Enhanced - Tampa Bay area, FL. Just buy me dinner + fuel
Demoh is offline   Reply With Quote Quick reply to this message
Old 06-11-2010, 12:25 PM   #7 (permalink)
Junior Member
 
Join Date: Jun 2010
Location: HIGGANUM, CT
Posts: 4
My Photos: (0)
Feedback Score: 0 reviews
I am looking at going toward detroit as The kit was $220 for just the clithces and spacers. There is an issue if setting the spring force based on the stack up. Ford has some special tool to set this. Not sure exactly what it sets. If i new details I probably counld Engineer a way out of using that particular tool. Tool number is 205-135. kit number is f81z-4947-AA. That is for a 2 piece 3 pinion diff case with 10.5 ring gear LS. Dealer will charge 150-200 to rebuild carrier properly setting spring force distance. Not sure if they use tool or some other method.
sgreco410 is offline   Reply With Quote Quick reply to this message
Old 06-11-2010, 12:27 PM   #8 (permalink)
Junior Member
 
Join Date: Jun 2010
Location: HIGGANUM, CT
Posts: 4
My Photos: (0)
Feedback Score: 0 reviews
BTW, when i meant kit i meant the Ford clutch replacement kit. After said and done it will be close to $400. $600 to go to Detriot ball park. Something to think about.
sgreco410 is offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Reply

  Diesel Forum - TheDieselStop.com > 1999-2007 Ford Super Duties > 99 & up 7.3L Power Stroke Engine and Drivetrain

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Diesel Forum - TheDieselStop.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



Wheel & Tire Center

Powered by vBadvanced CMPS v3.2.3

All times are GMT -5. The time now is 02:20 AM.



Powered by vBulletin® Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Search Engine Friendly URLs by vBSEO 3.6.0

vBulletin Optimisation provided by vB Optimise (Pro) - vBulletin Mods & Addons Copyright © 2014 DragonByte Technologies Ltd.