Ford F150 Pickup. Instruction - part 635

Fig. 157: Installing Nut Over Top & Base Stud 
Courtesy of FORD MOTOR CO. 

7. Use special tool 303-D027 (D81L-4201-A) and select the thickest blade that will enter between the tool 

and the differential clutch pack. Subtract 0.010 inch from the reading to obtain the thickness of the new 
clutch shim. A maximum of two shims can be used. Select the correct shim(s) size and remove special 
tool 205-135 (T80P-4946-A). 

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 9.75-inch - F150 Pickup

  

Fig. 158: Shim Part Descriptions Table 
Courtesy of FORD MOTOR CO. 

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 9.75-inch - F150 Pickup

  

Fig. 159: Differential Clutch Pack Measuring Point 
Courtesy of FORD MOTOR CO. 

8. Place the shim and Belleville spring on the differential clutch pack. 

z

The dished or concave side of the Belleville spring must face up and against the thrust face of the 
differential case. 

z

Refer to the exploded view in Description and Operation. 

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 9.75-inch - F150 Pickup

  

Fig. 160: Placing Shim & Belleville Spring On Differential Clutch Pack 
Courtesy of FORD MOTOR CO. 

9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the 

differential case. 

z

Hold the upper clutch pack and side gear assembly in place to prevent it from falling out of the 
differential case.  

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 9.75-inch - F150 Pickup