F 550 4WD Super Duty V10-6.8L VIN S (2000)
CAUTION: Oil the bearings immediately, to prevent rusting.
CAUTION: If upon inspection, any component has score marks/chips, thoroughly clean the differential housing.
Carry out the following inspection.
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Thoroughly clean all parts.
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Inspect all parts for damage.
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Discard the complete differential if excessive wear is visible on all parts.
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Discard both differential pinion gears and both differential side gears if any one of these gears are worn/damaged.
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Verify that the differential bearing bores are smooth. Remove any nicks/burrs from the mounting surfaces of the differential housing.
Assembly
1. Place the differential case into a vise with soft jaws.
2. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-I9590-A or equivalent meeting Ford specification ESA-M1C198-A to
the following.
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The differential side gear thrust washers.
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The differential side gear hubs and thrust faces.
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The differential pinion thrust washers.
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The differential pinion gears.
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Assemble the gears and their respective washers.
3. Lubricate the gears with SAE 8OW-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2CI97-A,
and install them into the differential case.
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Install and hold the differential side gears and thrust washers in the differential case. Then, install the differential pinion gears and thrust
washers, and rotate them until the pinion shaft bore in the case and gears align.
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If hand rotation of the gears is not possible, install an axle shaft into the differential side gear, and turn the shaft with a pipe wrench.
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If necessary, use a drift to align the pinion shaft bores.
4. Install the differential pinion shaft, aligning the lock pin bore in the differential case and the pinion shaft.
