Ford F150 Pickup. Instruction - part 636

Fig. 161: Inserting Differential Clutch Packs With Shims Into Differential Case 
Courtesy of FORD MOTOR CO. 

NOTE:

Apply a small amount of grease to the step plate bore.

 

2003 Ford Pickup F150 

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

  

10. 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. 

Fig. 162: Assembling Special Tool To Differential Case 
Courtesy of FORD MOTOR CO. 

NOTE:

If necessary, insert the dowel bar in the nut bore to keep the nut from 
turning as the hex screw is tightened.

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.

 

2003 Ford Pickup F150 

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

  

Fig. 163: Positioning Differential Pinion Gears 
Courtesy of FORD MOTOR CO. 

11. 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. 

WARNING:

Keep fingers/hands away from pinion gears when rotating the 
differential case with the differential rotating tool.

 

2003 Ford Pickup F150 

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

  

Fig. 164: Inserting Special Tool Into Pinion Shaft Bore 
Courtesy of FORD MOTOR CO. 

12. 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.  

13. Loosen the forcing screw, and remove the step plate and nut from the side gear bores. Install a new 

differential pinion shaft in the differential case. 

z

Install the differential pinion shaft lock bolt finger-tight. 

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.

 

2003 Ford Pickup F150 

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