Some 2010-2011 F-150 vehicles equipped 9.75 rear axle assembly may exhibit a shudder, chatter and/or vibration during slow, tight turns more and noticeable after cold startup. Concern maybe less noticeable once rear axle fluid warms up.

2010 Ford Truck F 150 4WD V8-4.6L VIN 8   Page 1
Vehicle: All Technical Service Bulletins
Drivetrain - Rear Axle Chatter/Shudder On Slow Turns
TSB 11-11-6
11/10/11
9.75 REAR AXLE CHATTER - SHUDDER - VIBRATION
ON SLOW TURNS
FORD:
2010-2011 F-150
ISSUE
Some 2010-2011 F-150 vehicles equipped 9.75 rear axle assembly may exhibit a shudder, chatter and/or vibration during slow, tight turns more and
noticeable after cold startup. Concern maybe less noticeable once rear axle fluid warms up.
ACTION
Follow service procedure to correct the condition.
SERVICE PROCEDURE
Insure the vehicle is equipped with original equipment 9.75 rear axle assembly before making repairs.
Prior to starting with this procedure, soak all new friction (tabbed) plates from the kit in additive friction modifier for a minimum of 15 minutes.
Save the additive friction modifier to install at the completion of this procedure.
1. Remove the rear differential carrier assembly. Refer to Workshop Manual (WSM), Section 205-02B.
2. Install the differential gauge (205-384) in a suitable vise.
3. Install the differential carrier onto the gauge.
a. Apply a small amount of grease to the centering hole of the differential gauge.
4. Using tool 205-386, Install the differential gauge in the bottom differential side gear.
5. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until
contact is made with the step plate.
a. The dowel bar is used to keep the nut from turning when the forcing screw is tightened.
6. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gears away from the differential pinion
gears.
a. Differential pinion gear thrust washers cannot be removed independently of the differential pinion gears.
7. Using tool 205-378, insert the differential rotator in the pinion shaft bore and turn the differential case to walk the differential pinion gears and
differential pinion gear thrust washers out to the differential case windows.
8. Remove the differential pinion gears and differential pinion gear thrust washers.
9. Remove the differential side gears, thrust washers and differential clutch packs with the selective shim and belleville spring and tag them RH and
LH.
10. Discard old clutch packs including shims as this kit contains all clutch plates and shims required for rebuild. Reuse belleville spring.
11. Assemble the differential clutch packs without the selective shims and belleville springs on their respective differential side gears.
12. Clamp the bolt head of the differential gauge in a vise (205-386).
13. Install the differential clutch pack and the differential side gear without the selective shim or the belleville spring on the differential gauge.
14. Position the differential clutch gauge on top of the differential clutch pack 205-135.
15. Install the differential gauge over the disc and differential clutch pack.
16. Install the nut over the top and base stud. Tighten to 7 N.m (62 lb-in).
a. Selective shims are available as part of the Clutch Pack Replacement Kit.
2010 Ford Truck F 150 4WD V8-4.6L VIN 8   Page 2
17. Use the feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack. Subtract 0.0075" from the
reading. Then select the closest thinner thickness selective shim, that will be the new selective shim that should be used.
18. Place the selective shim and belleville spring on the differential clutch pack. The dished or concave side of the belleville spring must face up
against the thrust face of the differential case.
19. Repeat Steps 17-18 for other the side of clutch pack.
20. Install the differential side gears with the differential clutch packs, selective shims and belleville spring into the differential case.
21. Hold the differential side gear assembly in place to prevent it from falling out of the differential case.
a. Apply a small amount of grease to the step plate bore.
b. If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.
22. Using tool 205-386, assemble the differential gauge to the differential case.
23. Position the differential gauge in the bottom differential side gear.
24. Position the differential gauge in the top differential side gear and hold it in place.
25. Install the differential gauge and tighten it 2 turns afler it contacts the bottom step plate.
a. Lubricate both sides of the differential pinion gear thrust washers with axle lubricant.
b. Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.
26. Position the differential pinion gears and differential pinion gear thrust washers in the window of the differential case so they mesh with the
differential side gear teeth.
a. It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.
27. Insert the differential rotator into the pinion shaft bore 205-378, and turn the differential case. This will cause the differential pinion gears to
engage the differential side gears and walk into the differential case. Rotate the differential case until the pinion shafi mating holes are lined up
exactly with the holes in the differential pinion gears.
28. Remove the differential gauge.
29. Install differential pinion shaft and new differential pinion shaft lock bolt from the kit finger-tight.
30. Install the rear differential carrier assembly. Refer to WSM, Section 205-02B.
31. Drive slowly while making left and right tight turns.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty/ESP coverage limits/policies are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified
causal part and verified using the OASIS part coverage tool.
OPERATION DESCRIPTION TIME
111106A 2010-2011 F-150 Equipped 2.5 Hrs.
With 9.75 Rear Axle:
Replace Rear Axle
Limited-Slip Clutch Packs
Following The Service
Procedure (Do Not Use
With Any Other Labor
2010 Ford Truck F 150 4WD V8-4.6L VIN 8   Page 3
Operation)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4947 42
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