Ranger 4WD L4-134 2.2L DSL (1983)
9.
Mount differential cover in suitable vise.
10.
Insert shims .050 inch total thickness, in cover cavity.
11.
Install composite plate on back side of clutch hub with friction material against hub, then install, in order, a friction plate, steel plate, friction plate,
steel plate, friction plate and steel plate.
12.
Place clutch hub with clutch plates into clutch gear cavities in differential cover, ensuring that splines on last friction plate are engaged on hub.
13.
Obtain locally a 5/8 inch by 2-1/2 inch or 9/16 inch by 2-1/2 inch bolt, nut, and two 1-1/2 inch O.D. flat washers approximately 1/8 inch in
thickness. Install flat washer on bolt and place bolt through clutch hub. Hold bolt in place and turn cover over. Plate flat washer and bolt and
install nut, torquing nut to 10---15 ft. lbs. while ensuring that washers remain centered.
Fig. 11 Shim pack thickness chart
14.
Place shim template tool in clutch hub, Fig. 11. Some clearance should be observed between shim tool and cover to case mating surface.
Determine exact amount of clearance using feeler gauge. The shim pack thickness chart, Fig. 12, will indicate correct amount of shims to subtract
from .050 inch shims originally installed.
15.
Remove bolt, nut and flat washers. Remove clutch hub and clutch plates as necessary to alter shim thickness.
16.
Install selected shims in cover cavity, then reinstall components as described in steps 11 and 12.
17.
Install four steel clutch ear guides and side gears.
18.
Place both assemblies in press and press two halves together, then install two Allen head or Phillips head screws and tighten evenly until tight.
19.
Install ring gear and ring gear bolts and washers. Torque bolts evenly and alternately across diameter of ring gear to 70---80 ft. lbs.
20.
Using currently released locker tools, check torque required to rotate one side gear while other is held stationary. The initial breakaway torque may
exceed 250 ft. lbs. The rotating torque required to keep the side gear turning with new clutch plates is 100---250 ft. lbs. With reused clutch plates,
the minimum torque required is 40 ft. lbs. (Torque may fluctuate 10---40 ft. lbs.)
