Ford F150 Pickup. Manual — part 549

Fig. 176: Inserting Differential Clutch Packs With Shims
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 10.25-inch - F150 Pickup

Fig. 177: Assembling Forcing Screw, Nut & Step Plate
Courtesy of FORD MOTOR CO.

10. Assemble the forcing screw, nut and step plate to the differential case.

1. Position the step plate in the bottom side gear bore.

NOTE:

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

2003 Ford Pickup F150

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 10.25-inch - F150 Pickup

2. Position the nut in the top side gear bore and hold it in place.

3. Install the hex-head screw and tighten it two turns after it contacts the bottom step plate.

NOTE:

Prelubricate both sides of the differential pinion thrust washers with high
performance rear axle lubricant.

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 10.25-inch - F150 Pickup

Fig. 178: Installing Differential Pinion Gears & Differential Pinion Thrust Washers
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 10.25-inch - F150 Pickup