Differential Clutch Replacement

[crouse]

Has anyone changed the clutches in your differential? I can't seem to find much information on this. Wondering if this is something I can do myself or just leave it to the pros? Does the carrier have to be removed to replace the clutches? Are there different type of clutches? Thanks, Curt

[Blackened300a]

There is a kit available with carbon fiber clutches, bolts, gasket, and a upgraded "S" spring.
1) Remove rear tires and brake calibers.
2) Remove rear diff cover.
3) Spin diff around to remove the 7mm bolt on the top of the carrier to remove the center pin, then pull the pin out.
4) Remove the "S" spring
5) Remove the bolts holding the ABS sensors in and pull the sensors out.
6) Push the axles all the way in and remove the "C" clips on the axle ends
7) Remove the spider gears, There is a thin shim on the top and bottom of the upper and lower spider gears. Be careful with them, they are fragile.
8) Remove the spider gears on the left and right, the clutch packs are behind them with shims. They must be installed the same way with the same amount of shims and clutches. Its also recommended to let the new clutches soak in the friction modifier before the install.
9) Reinstall the clutches and spider gears, you'll need to slide the axles back into the left and right spider gears because you'll need to turn them at the same time to pull in the upper and lower spider gears all while not breaking the shims in the process.
10) If you pull step 9 off and are still into finishing this job, you can get a giant rubber mallet and a set of vice grips to reinstall the bigger "S" spring into the carrier.
11) After screaming and yelling for the last hour, but still managed to get the spring back in, you can reinstall the axle "C" clips and put the center pin back in with a NEW bolt to hold it all together.
12) Reinstall the ABS sensor bolts with the sensors in place
13) Reinstall the rear brakes and put the tires back on
14) Reinstall diff cover with new gasket and silicone.
15) Fill diff with oil that either has friction modifier in it or purchase the FM additive from a Ford dealer.
16) Go wash your hands and swear off never doing this job again. :D

The diff don't have to be removed, but its a complete PITA to do this by yourself especially without a lift. I suggest getting price quotes, it shouldn't be all that expensive and save you a lot of aggrivation.

[RacerX]

Nice writeup. Didn't someone else here say not to presoak the clutch packs so they're easier to install?

[MOTOWN]

i recently replaced mines w/stock replacements, very straight forward, if you can spin a wrench, you can do this!
worst part for me was laying on cold concrete

[Blackened300a]

Nice writeup. Didn't someone else here say not to presoak the clutch packs so they're easier to install?

They claim that the pre-soak makes them swell up. The fraction of a millimeter wouldn't make a difference during the installation. Its such a tight tolerance, you'll want some oil in between the clutches just to keep them intact.

[RacerX]

worst part for me was laying on cold concrete
You're not married I take it??? :D

[MOTOWN]

You're not married I take it??? :D


lol happily divorced since 04', now im married to motorsports;)

[yjmud]

ford say to soak them

[crouse]

Thanks for the info. I helped the guy who installed my gears and I remember the c-clips and spring were a pain. There is a Master Transmission here in Rosemount that does good work. I think I'll get an estimate.

[GreekGod]

...it is easy to break the OEM spring trying to get it back in, and the HD (F150?) spring might be even more difficult to install. The OEM spider gears are no longer available, and subject to failure (I don't know if the replacements will work in the OEM differential).

[Dragcity]

Someone has a Tru trac for sale... no more clutches.!

[fastblackmerc]

I have a DVD on rebuilding the Ford 8.8 rear. If I find it I'll make a few copies to send out for the cost of postage.

[BigCars4Ever]

http://www.mercurymarauder.net/forums/showthread.php?t=69156
A few posts in I have a small write up with some tips I learned.

[Rockettman]

I have a DVD on rebuilding the Ford 8.8 rear. If I find it I'll make a few copies to send out for the cost of postage.

:hmmm: I have a PM box here if/when that happens. :D