This procedure replaces the limited slip clutch pack in the rear differential of a 2011-2014 Ford F-150 4WD with the 5.0L Coyote engine, restoring proper traction control functionality.

Warnings

Tools required

Parts

• Limited slip clutch pack kit (OEM or equivalent) × 1 — Ford Motorcraft or equivalent for 9.75" rear differential
• Differential cover gasket × 1 — Use OEM specification
• Friction modifier additive for limited slip × 1 — Ford XL-3 or equivalent
• Differential pinion seal × 1 — Use OEM specification
• Axle seals (left and right) × 2 — Use OEM specification
• Differential bearing shims (assorted) × 1 — Use OEM specification
• Thread locker (medium strength) × 1 — Loctite 242 or equivalent

Fluids

• Motorcraft 75W-140 Synthetic Gear Oil — 3 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels securely
3. Raise rear of vehicle and support with jack stands under frame rails
4. Remove both rear wheels
5. Mark driveshaft and pinion flange orientation for proper reinstallation
6. Place drain pan under differential
7. Clean exterior of differential housing thoroughly to prevent contamination during disassembly
8. Verify differential type by locating identification tag on cover - should indicate limited slip and 9.75" ring gear

Procedure

1. 1

   Remove driveshaft and drain differential
   Remove the four U-joint strap bolts connecting the driveshaft to the rear pinion flange. Support driveshaft and slide it rearward to disconnect from pinion. Secure driveshaft out of the way. Remove all differential cover bolts in a crisscross pattern and carefully pry cover off using a flat blade screwdriver. Allow gear oil to drain completely into drain pan.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)

   Differential Cover Bolts35 Nm (26 lb-ft)
2. 2

   Remove axle shafts
   From inside the differential, remove the differential pinion shaft lock bolt. Carefully slide out the pinion shaft. Push each axle shaft inward and remove the C-clip retainers from the inner end of each axle shaft. Withdraw both axle shafts from the housing and set aside on clean surface. Inspect axle shaft splines for wear or damage.
3. 3

   Remove carrier assembly
   Remove the four carrier bearing cap bolts. Mark the bearing caps and housing for proper reassembly orientation. Install differential spreader tool on the housing and slowly spread the housing approximately 0.015" (no more than 0.020"). Use dial indicator to monitor spread. Carefully pry the carrier assembly out of the housing using pry bars on both sides simultaneously. Remove spreader tool immediately after carrier is out to prevent housing distortion.
   ⚠️Do not spread differential housing more than 0.020" or permanent damage will occur. Use dial indicator to monitor spread precisely.
4. 4

   Disassemble carrier and measure backlash
   Before disassembly, measure and record ring gear backlash using dial indicator - this will be your baseline. Mark the relationship between ring gear and carrier. Remove ring gear bolts and separate ring gear from carrier using soft mallet if necessary. Remove bearing caps from carrier and mark them for proper orientation. Using bearing puller, remove both carrier bearings and keep all shims organized by side. Record shim thickness measurements for reassembly reference.
5. 5

   Remove differential pinion shaft and cross pin
   Drive out the differential cross pin (pinion shaft) roll pin using appropriate drift punch. Remove the cross pin. Remove both pinion gears and thrust washers, keeping them organized. Remove both side gears and their thrust washers from the carrier. Keep all components organized and inspect for wear patterns, scoring, or damage.
6. 6

   Remove old clutch pack
   Remove the old limited slip clutch pack assemblies from both sides of the carrier. Note the orientation and arrangement of clutch plates and friction discs. Clean the carrier thoroughly using brake cleaner or mineral spirits, removing all old gear oil and debris. Inspect carrier for cracks, wear, or damage. Check splines on side gear bores for wear or damage that would affect new clutch pack operation.
7. 7

   Install new clutch pack
   Soak new friction plates in 75W-140 gear oil for 30 minutes before installation. Install new clutch pack assemblies according to manufacturer's instructions, ensuring proper alternating pattern of steel plates and friction discs. Verify correct orientation - typically friction disc first, then alternating steel and friction plates. Apply light coat of gear oil to each component during installation. Ensure clutch packs are fully seated in their bores.
   ℹ️Clutch plate orientation and count is critical. Reference the parts kit instructions for exact sequence and quantity.
8. 8

   Reassemble differential internals
   Install side gears with new thrust washers into carrier, ensuring they engage properly with clutch packs. Install pinion gears with their thrust washers onto the cross pin. Insert cross pin through carrier and pinion gears, aligning roll pin hole. Check that all gears rotate smoothly with appropriate resistance from clutch packs. Install new roll pin to secure cross pin, ensuring it is fully seated below the carrier surface.
9. 9

   Install ring gear and set bearing preload
   Clean ring gear and carrier mating surfaces thoroughly. Apply medium-strength thread locker to ring gear bolt threads. Install ring gear to carrier in original orientation per match marks. Torque ring gear bolts in star pattern to specification. Press carrier bearings onto carrier hubs using appropriate bearing installation tools or press. Install original shims on both sides as starting point for bearing preload adjustment. Bearing preload will be finalized after carrier installation.
10. 10

    Install carrier assembly and set backlash
    Install differential spreader and spread housing to same 0.015" as during removal. Carefully install carrier assembly into housing, ensuring bearing races are properly seated. Remove spreader immediately. Install bearing caps in their original positions per match marks. Torque bearing cap bolts to specification. Measure ring gear backlash using dial indicator at four points around the ring gear. Backlash should be 0.008-0.012" (0.20-0.30mm). Adjust by moving shims from one side to the other - moving shims to ring gear side decreases backlash, moving away increases it.
    ⚠Backlash must be within specification and consistent around the entire ring gear. Out-of-spec backlash causes noise and premature wear.
11. 11

    Check gear contact pattern
    Apply thin coat of gear marking compound to 8-10 teeth on the ring gear. Rotate ring gear through several complete revolutions in both directions while applying moderate resistance. Examine tooth contact pattern on drive and coast sides. Pattern should be centered on tooth face with proper toe and heel contact. If pattern is incorrect, adjust by changing pinion depth shims (requires pinion removal - beyond scope if not already planned). For clutch pack replacement only, pattern should match original if pinion was not disturbed.
12. 12

    Install axle shafts and pinion shaft
    Apply light coat of gear oil to axle shaft splines and sealing surfaces. Carefully insert both axle shafts into housing, avoiding damage to new seals. Push axle shafts inward and install C-clip retainers into grooves on inner ends. Verify C-clips are fully seated. Insert differential pinion shaft through carrier and align lock bolt hole. Apply thread locker to lock bolt and install, torquing to specification. Verify axle shafts cannot be pulled outward past C-clips.
13. 13

    Install differential cover and fill with fluid
    Clean differential cover and housing mating surfaces thoroughly, removing all old gasket material. Install new differential cover gasket - do not use RTV unless specified by gasket manufacturer. Install differential cover and torque bolts in crisscross pattern to specification. Fill differential with 2.0 quarts of Motorcraft 75W-140 synthetic gear oil through fill hole. Add one bottle of friction modifier additive specifically designed for limited slip differentials (typically 4 oz). Install fill plug and torque to specification. Check for leaks around cover.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
14. 14

    Reinstall driveshaft and wheels
    Align driveshaft to pinion flange per match marks made during disassembly. Install U-joint strap bolts and tighten evenly in crisscross pattern to prevent binding. Install rear wheels and torque lug nuts in star pattern. Lower vehicle from jack stands. Remove wheel chocks.
    Torque spec

    Driveshaft U-Joint Straps20 Nm (15 lb-ft)

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Double-check that all bearing cap bolts are torqued to specification
2. Verify differential cover bolts are properly torqued and cover gasket is not leaking
3. Ensure driveshaft U-joint straps are torqued evenly to prevent vibration
4. Confirm axle shafts are retained by C-clips and cannot be pulled out
5. Recheck fluid level after initial test drive - top off if necessary

Verification

• Start engine and shift transmission through all gears with vehicle stationary - no abnormal noises should be present
• Test drive vehicle in safe area, making gentle turns in both directions - limited slip should provide smooth operation without chattering
• Perform moderate acceleration from stop - both rear wheels should drive equally without excessive wheel spin on one side
• Check for fluid leaks around differential cover, pinion seal, and axle seals after test drive
• Verify no vibration is present at highway speeds - indicates proper driveshaft installation and balance
• Limited slip operation should be smooth without chattering during slow-speed turns - chatter indicates insufficient friction modifier or improper clutch pack installation
• After 50-100 miles of driving, recheck differential fluid level and top off if needed
• Monitor for any unusual noises during normal operation for first 500 miles - howling or whining indicates incorrect backlash or bearing preload

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