Ford F-150 1999 Workshop Manual page 5

1999 F-150/250 Workshop Manual
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 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 special tool to the differential case.
1. Position the special tool in the bottom side gear bore.
2. Position the special tool in the top side gear bore and hold it in place.
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.
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 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.
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11/3/2009