F 250 4WD Super Duty V10-6.8L VIN S (2001)
9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case.
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Hold the upper differential clutch pack and side gear assembly in place to prevent it from failing 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 forcing screw, nut and Step Plate to the differential case.
1
Position the Step Plate in the bottom side gear bore.
2
Position the nut in the top side gear bore and hold it in place.
3
Install the hex-head screw 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-I9580-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 ringers/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.
