In-Vehicle Adjustments

In-vehicle adjustments are possible on this unit without removing the rear axle housing (4010) . If the testing check was not to specification, the following procedure can be used to correct the condition:

NOTE: Whenever replacing the rear axle lubricant, use Rear Axle Lubricant XY-90-QL (ESP-M2C154-A) or equivalent meeting Ford specification ESP-M2C154-A.

Removal

1. Raise the vehicle on a hoist and install safety stands. Refer to Section 00-02. Remove rear wheels (1007) and the calipers and rotors. Refer to Section 06-04.

2. Remove axle housing cover (4033) from rear axle housing rear face and drain lubricant.

3. Perform the inspection before disassembly.

4. Working through the cover opening, remove the differential pinion shaft lock pin (4241) and remove the differential pinion shaft (4211) .

5. Push axle shafts (4234) inward until the rear axle shaft retaining u-washers (4N237) at the button end of shafts are clear of the side gear recess.

    CAUTION: Care should be taken not to damage the inner wheel bearing oil seal (1177) when removing the axle shafts from the rear axle housing . In addition, the axle shafts must be completely removed from the rear axle housing .

6. Remove the rear axle shaft retaining u-washers and pull the axle shafts out of the rear axle housing .
   
   
   
   

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

7. With a suitable drift, drive the differential clutch spring half-way out of the differential case (4204) . Rotate the differential case 180 degrees.

8. Hold the differential clutch spring with a pair of pliers and tap the differential clutch spring until it is removed from the differential case .

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

9. Using Gear Rotator-Traction-Lok T80P-4205-A, rotate the differential pinion gears until the gears can be removed from the differential case .
   
   
   
   

10. Remove the RH and LH differential side gear (4236) and differential clutch pack (4947) with the rear axle differential clutch shim (4A324) and tag them "RH" and "LH" side.

    NOTE: Do not use cleaning solution on clutch plate surfaces. Wipe clean only.

11. Inspect the differential clutch packs for wear and replace parts as necessary.

Installation

1. Install the LH differential side gear , differential clutch pack and new rear axle differential clutch shim into the cavity in the differential case . Repeat this step for the RH side.

2. Place the differential pinion gear and differential pinion thrust washer (4230) 180 degrees apart on the differential side gears .

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