Ford F150 Pickup. Instruction - part 548

Fig. 172: Installing Gauge Nut Over The Top & Base Stud 
Courtesy of FORD MOTOR CO. 

7. Use a Feeler Gauge and select the thickest blade that will enter between the tool and the differential 

clutch pack. Subtract .010-inch from the reading to obtain the thickness of the new clutch shim. A 
maximum of two shims may be used. Select the correct shim(s) size and remove the Traction-Lok Clutch 
Gauge. 

 

2003 Ford Pickup F150 

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

  

Fig. 173: Clutch Shim Specifications 
Courtesy of FORD MOTOR CO. 

 

2003 Ford Pickup F150 

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

  

Fig. 174: Checking Clutch Shim Clearance 
Courtesy of FORD MOTOR CO. 

8. Place the shim and Belleville spring on the differential clutch pack. 

z

The dished or concave side of the Belleville spring must face up and against the thrust face of the 
differential case.  

z

For additional information, refer to the exploded view in DESCRIPTION AND OPERATION . 

 

2003 Ford Pickup F150 

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

  

Fig. 175: Placing Shim & Belleville Spring On Differential Clutch Pack 
Courtesy of FORD MOTOR CO. 

9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the 

differential case. 

z

Hold the upper differential clutch pack and side gear assembly in place to prevent it from falling 
out of the differential case. 

 

2003 Ford Pickup F150 

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