This procedure covers the replacement of the limited slip differential clutch pack in the rear axle of a 2015-2020 Ford F-150 with 5.0L V8 engine, requiring removal of the differential carrier assembly.

Warnings

Tools required

Parts

• Limited slip clutch pack kit (includes friction and steel plates) × 1 — Use OEM specification for axle ratio
• Differential cover gasket × 1 — Use OEM specification
• Differential carrier bearing shims (if needed) × 1 — Determine size after measurement
• Friction modifier additive for limited slip × 1 — Motorcraft XL-3 or equivalent
• RTV silicone gasket maker (if reusable gasket not available) × 1 — Motorcraft TA-30 or equivalent

Fluids

• Motorcraft 75W-140 Synthetic Gear Oil — 2.5 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 using star pattern loosening sequence
5. Mark driveshaft-to-pinion flange orientation with paint or marker for proper reinstallation alignment
6. Place drain pan under differential and allow gear oil to drain completely after removing cover
7. Clean all components with brake cleaner and inspect for wear or damage

Procedure

1. 1

   Remove differential cover and drain fluid
   Loosen all differential cover bolts gradually in a crisscross pattern to prevent warping. Remove bolts completely and carefully pry cover away from housing using a plastic scraper or pry tool. Allow gear oil to drain completely into drain pan. Remove and discard old gasket material from both cover and housing mating surfaces. Clean surfaces thoroughly with brake cleaner.
   Torque spec

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

   Remove driveshaft from pinion flange
   Remove the four driveshaft bolts connecting the driveshaft yoke to the pinion flange. Support the driveshaft and carefully lower it away from the differential, being careful not to let universal joint caps fall off. Secure driveshaft out of work area or remove completely if necessary.
   Torque spec

   Driveshaft Bolts94 Nm (69 lb-ft)
3. 3

   Mark and measure bearing cap orientation
   The differential carrier bearing caps are machined as a matched set with the housing. Use a center punch or permanent marker to mark the caps and housing so they can be reinstalled in exact original orientation. Use a dial indicator to measure and record the ring gear backlash at multiple teeth around the ring gear. This baseline measurement is critical for proper reassembly.
4. 4

   Remove carrier bearing caps
   Remove the bolts securing both carrier bearing caps. Caps may be tight in their bores. Tap gently with a dead blow hammer if needed, keeping caps aligned with housing to prevent damage. Keep bearing caps, bolts, and any shims together and labeled for their specific side (ring gear side and opposite side).
   ⚠Bearing caps and housing are matched sets. Installing caps reversed or on wrong sides will cause immediate bearing failure.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
5. 5

   Remove differential carrier assembly
   Install differential spreader tool on housing according to tool manufacturer instructions. Spread housing ONLY enough to allow carrier removal (typically 0.010-0.015 inches maximum). Mount dial indicator to measure spread and do not exceed 0.020 inches or housing will be permanently damaged. Carefully pry carrier assembly out of housing using pry bars. Remove spreader tool immediately after carrier is removed.
   ⚠️Over-spreading the differential housing beyond 0.020 inches will cause permanent distortion and housing failure. Monitor dial indicator constantly during spreading.
6. 6

   Disassemble differential case
   Mount differential carrier assembly in a holding fixture or soft-jawed vise (clamp on ring gear only, never on carrier housing). Remove ring gear bolts if needed for access. Remove differential pinion shaft lock bolt and slide pinion shaft out of carrier. Rotate side gears to align with pinion gear windows and remove pinion gears, side gears, and thrust washers. Keep all components organized.
   ℹ️Take photos during disassembly to ensure proper reassembly sequence, especially noting orientation of thrust washers and gear positioning.
7. 7

   Remove old clutch pack
   Remove the limited slip clutch pack assembly from the differential case. Note the exact sequence and orientation of friction plates and steel separator plates. Count plates and measure overall stack height with calipers for comparison with new clutch pack. Inspect case for scoring or wear that would prevent proper clutch operation.
   ℹ️Friction plates and steel plates alternate in the clutch pack. New clutch pack must be installed in same sequence as original.
8. 8

   Install new clutch pack
   Clean differential case clutch pack bores thoroughly with brake cleaner. Soak new friction plates in 75W-140 gear oil with friction modifier for at least 15 minutes before installation. Install new clutch pack in proper sequence alternating friction and steel plates as shown in kit instructions and matching original configuration. Ensure plates seat fully in case. Measure final stack height and compare to specifications and old pack measurement.
   ⚠Friction plates must be soaked in gear oil before installation to prevent initial clutch binding and premature wear.
9. 9

   Reassemble differential internals
   Install side gears with thrust washers in proper orientation. Install pinion gears with thrust washers, ensuring gears mesh properly with side gears. Rotate side gears to verify smooth operation. Install pinion shaft through case and gears, aligning lock bolt hole. Install and torque pinion shaft lock bolt per manufacturer specification. Verify side gear rotation is smooth with slight resistance from clutch pack preload.
10. 10

    Install carrier assembly into housing
    Install differential spreader tool on housing and spread to same measurement used during removal (monitor with dial indicator). Ensure original shims are positioned on carrier bearing races in their original locations. Carefully lower carrier assembly into housing, ensuring bearings seat properly in their bores. Remove spreader tool immediately after carrier is seated.
    ⚠Shims must be returned to their original positions unless backlash adjustment is required. Incorrect shimming will cause improper gear mesh and noise.
11. 11

    Install bearing caps and check backlash
    Install bearing caps in their original marked positions with original bolts. Torque bearing cap bolts to specification. Mount dial indicator on housing with plunger contacting ring gear tooth face. Check ring gear backlash at minimum four positions around the gear. Backlash should match original measurement within 0.002 inches and be within manufacturer specification (typically 0.005-0.009 inches). If backlash is incorrect, shims must be moved between carrier bearings.
    ℹ️Moving shims from ring gear side to opposite side increases backlash. Moving shims from opposite side to ring gear side decreases backlash.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
12. 12

    Install driveshaft
    Align driveshaft yoke to pinion flange using alignment marks made during disassembly. Install driveshaft bolts and torque to specification in a crisscross pattern. Verify driveshaft rotates freely without binding.
    Torque spec

    Driveshaft Bolts94 Nm (69 lb-ft)
13. 13

    Install differential cover and fill with fluid
    Install new differential cover gasket or apply thin bead of RTV silicone to cover mating surface. Position cover on housing and install all bolts finger-tight. Torque cover bolts to specification in a crisscross pattern starting from center and working outward. Fill differential with 2.0 quarts of Motorcraft 75W-140 synthetic gear oil through fill plug opening. Add friction modifier additive per bottle instructions (typically 4 oz). Install fill plug and torque to specification.
    ⚠Limited slip differential requires friction modifier additive. Failure to add modifier will cause clutch chatter and premature wear.
    Torque spec

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

    Reinstall wheels and lower vehicle
    Reinstall rear wheels and torque lug nuts to specification using star pattern sequence. Lower vehicle from jack stands to ground. Perform final lug nut torque check with vehicle weight on wheels.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all bearing caps are installed in original marked positions
2. Verify ring gear backlash is within specification before buttoning up
3. Double-check that friction modifier additive was added to gear oil
4. Confirm driveshaft alignment marks match before final torque
5. Perform final torque verification on all fasteners after initial test drive

Verification

• Start engine and verify no abnormal noises from differential
• Test drive vehicle and perform figure-eight turns in both directions at low speed to verify clutch pack operation
• Listen for clutch chatter during slow turns - chattering indicates insufficient friction modifier
• Check for gear oil leaks around differential cover after test drive
• Verify limited slip operation by performing controlled single-wheel spin test on dry pavement - both rear wheels should turn together
• Recheck differential cover bolts and fill plug for tightness after 50 miles of driving
• Monitor for unusual noises, vibrations, or leaks during first 500 miles of operation

More procedures for this vehicle