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39.
CAUTION: Do not use acids or solvents when cleaning the differential clutch packs.
Wipe the components only with a clean, lint- free cloth.
Clean and inspect the differential clutch packs for wear and damage. Install new parts as
necessary.
Assembly
Initial assembly 1. Coat the new differential drive pinion bearing cup(s) with lubricant. zUse SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580- B or equivalent
meeting Ford specification WSL- M2C192-A.
2. Using the special tool, install the differential drive pinion bearing cup(s). 1. Position the bearing cup(s) on the special tool.
2. Position the special tool and the bearing cup(s) in the differential housing.
3. Tighten the special tool to fully seat the bearing cup(s) in the bore(s).
3. NOTE: Apply a light film of SAE 75W- 140 High Performance Rear Axle Lubricant F1TZ-19580-
B or equivalent meeting Ford specification WSL-M2C192- A on the front and rear pinion Klj . 15 ba
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bearings.
Install the pinion bearings and special tools as shown.
4. NOTE: This step duplicates pinion bearing preload.
Thread the special tool onto the Screw and tighten to the specification shown.
5. CAUTION: Offset the special tool to obtain an accurate reading. Item Part Number Description
1 205-
109 Adapter for 205-
S127 2 205-
105 Adapter for 205-
S127 3 4630 Rear (inner) pinion bearing
4 205-
129 Adapter for 205-
S127 5 205-
110 Adapter for 205-
S127 6 4621 Front (outer) pinion bearing
7 205-
111 Adapter for 205-
S127 Klj . 16 ba
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Rotate the special tool several half turns to seat the pinion bearings. Position the special tool as
shown.
6. Install the special tool. 1. Position the special tool on the differential housing differential bearing seat.
2. Install the differential bearing caps.
3. Install the bolts.
7. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. A
slight drag indicates correct shim selection.
8. Remove all of the special tools.
9. CAUTION: Use the same pinion bearings and drive pinion bearing adjustment shim
from the drive pinion bearing adjustment shim selection procedure for final assembly.
Position the drive pinion bearing adjustment shim and the pinion bearing on the drive pinion
gear stem.
10. Using the special tools and a suitable press, firmly seat the drive pinion bearing adjustment shim and pinion bearing on the drive pinion gear stem. Klj . 17 ba
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11. Install the front pinion bearing and the rear axle drive pinion shaft oil slinger in the differential
housing.
12. CAUTION: Installation without the correct tool can result in early seal failure.
CAUTION: If the seal becomes misaligned during installation, remove it and install a
new one.
NOTE: Coat the rear axle drive pinion seal lips with Premium Long- Life Grease XG-1-C or
equivalent meeting Ford specification ESA-M1C75- B.
Using the special tool, install the new rear axle drive pinion seal.
13. CAUTION: Make sure the splines on the drive pinion gear stem are free of burrs. If
burrs are evident, remove them using a fine crocus cloth, work in a rotational motion.
Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the
pinion stem shoulder. 14. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential Klj . 18 ba
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