Clutch Pack Preload Adjustments

NOTE: Lubricate friction plates with Additive Friction Modifier C8AZ-19B546-A or equivalent hypoid gear lubricant meeting Ford specification EST-M2C118-A prior to reassembly.

1. Install Traction-Lok Clutch Gauge T80P-4946-A on each of the side gear differential clutch packs (4947) without the rear axle differential clutch shim (4A324) . Tighten to 6.7 Nm (60 lb-in).
   
   
   
   

2. Using a feeler blade, 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 .
   
   
   
   

3. Prior to installation of locking the differential into a vehicle, a bench torque check must be made. With Traction-Lok Torque Tool T59L-4204-A, check the torque required to rotate one differential side gear (4236) while the other is held stationary.
   
   
   
   

   If original clutch plates are used, the initial breakaway torque should be at least 27 Nm (20 lb-ft). The rotating torque required to keep the differential side gear turning with new clutch plates may fluctuate with initial breakaway torque at least 271 Nm (200 lb-ft).
   
   
   
   

4. Clean the tapped holes in the ring gear with a suitable solvent. If the new rear axle differential gear case bolts (4216) to be used show a green coating over approximately 12.7mm (1/2 inch) of the threaded area, use as is. If not coated, apply a small amount of Stud and Bearing Mount E0AZ-19554-BA or equivalent meet Ford specification WSK-M2G349-A1. Tighten to 95-115 Nm (70-85 lb-ft).

5. For installation of differential case (4204) and ring gear, refer to Section 05-02B.