Ford F-150 1999 Workshop Manual
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1999 F-150/250 Workshop Manual
SECTION 205-02B: Rear Drive Axle/Differential — Ford 9.75-Inch Ring Gear
DISASSEMBLY AND ASSEMBLY
Differential Case and Ring Gear—Traction-Lok®
Special Tool(s)
2-Jaw Puller
205-D072 (D97L-4221-A) or equivalent
Installer, Differential Carrier Bearing
205-D044 (D81T-4221-A) or equivalent
15-101 Gauge, Differential Clutch (Excluding Mandrel)
205-135 (T80P-4946-A)
Feeler Gauge Set
303-D027 (D81L-4201-A) or equivalent
Rotator, Differential
205-378 (T97T-4205-C)
Gauge, Differential (Traction Lock)
205-386 (T97T-4205-D)
Step Plate
205-D019 (D80L-630-8) or equivalent
Gauge, Diferential (Traction-Lock) (Mandrel for 205-135 [T80P-4946-A])
205-389 (T97T-4946-A)
Gauge, Differential (Traction-Lock)
205-384 (T97T-4205-A)
Disassembly
1. Remove the differential case (4204). For additional information, refer to
2. NOTE: The differential bearings (4221) need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the special tool 205-D072 (D97L-4221-A)
and special tool 205–D019 (D80L-630–8) for differential case bearings.
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 differential ring gear and anti-lock speed sensor ring.
http://www.fordtechservice.dealerconnection.com/pubs/content/~WSX1/~MUS~LEN/20/S...
Differential Case
in this section.
Page 1 of 7
1999 F-150/250 Workshop Manual
Procedure revision date: 02/03/1999
11/3/2009
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Summary of Contents for Ford F-150 1999
- Page 1 2. NOTE: The differential bearings (4221) need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the special tool 205-D072 (D97L-4221-A) and special tool 205–D019 (D80L-630–8) for differential case bearings.
- Page 2 1999 F-150/250 Workshop Manual Page 2 of 7 3. Install the special tool in a suitable vise. 4. Install the differential case on the tool. 5. NOTE: Apply a small amount of grease to the centering hole of the special tool. Install the special tool in the bottom side gear bore.
- Page 3 Assembly 1. Prelubricate each steel clutch plate and soak all friction plates with 118 ml (4 ounces) 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.
- Page 4 1999 F-150/250 Workshop Manual Page 4 of 7 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 in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge. 4.
- Page 5 3. Install the special tool 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.
- Page 6 1999 F-150/250 Workshop Manual Page 6 of 7 13. Loosen the forcing screw, and remove the step plate and nut from the side gear bores. Install a new differential pinion shaft in the differential case. Install the differential pinion shaft lock bolt finger-tight. 14.
- Page 7 1999 F-150/250 Workshop Manual Page 7 of 7 http://www.fordtechservice.dealerconnection.com/pubs/content/~WSX1/~MUS~LEN/20/S... 11/3/2009...