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Principles of Operation Differential Electronic Module (DEM) and Active On-Demand Coupling The main role of the active on-demand coupling and the differential electronic module (DEM) is to regulate the all wheel drive (AWD) function by distributing torque between the front and rear axles. The system consists of a coupling that combines mechanical, hydraulic and electronic sections. The coupling unit is attached to the rear axle, between the differential gear and the driveshaft. The mechanical and hydraulic sections are driven by the driveshaft. Active on-demand coupling (AOC) has the following characteristics: Permanent AWD with electronic control of torque transfer front to rear 4X4 control module integrated into the DEM Similar to four wheel drive (4WD) operation No driveline wind-up during slow speed maneuvers or parking The system is not sensitive to size differences between the 4 road tires (when driving with a spare wheel, for example). The system is not sensitive to being towed with one axle raised. Inspection and Verification — Electronic Shift 1. Visually inspect for the following obvious signs of mechanical and electrical damage. Visual Inspection Chart Mechanical Axle shafts and universal joints Driveshaft and universal joints Rear differential Differential electronic module (DEM) Fluid leaks Matching tire size 2. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: check that the program card is correctly installed. check the connections to the vehicle. check the ignition switch position. 3. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual. 4. Carry out the DATA LINK DIAGNOSTICS test. If the scan tool responds with: CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418-00. NO RESP/NOT EQUIP for DEM, GO to Pinpoint Test A. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out the anti-lock brake system (ABS) module self-test. Carry out one key cycle after clearing codes. 5. If the DTCs retrieved are related to the concern, go to the 4X4 Control Module (DEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 6. NOTE: Not all DTCs cause the traction control indicator to illuminate. Refer to the table for specific DTCs. When the 4X4 control module (DEM) detects certain types of faults in the AWD system, a DTC is set and the traction control indicator will stay illuminated until the condition has been repaired and the DTCs are cleared using the scan tool. Carry out one key cycle after clearing codes. DTC P0562 System Voltage Low P0563 System Voltage High P0602 Powertrain Control Module (PCM) Programming Error P0606 ECM/PCM Processor Electrical Smart junction box (SJB) mini-fuse 19 (10A) Differential electronic module (DEM) Wiring harness Connector(s) Circuitry Description Traction Control Indicator State OFF OFF ON ON

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NOTE: Unless noted, the procedures in this section apply to both the conventional differential and the Truetrac® differential, though most of the illustrations used in the procedures show the conventional differential. The Model S135 rear axle features the following: a hypoid design differential ring gear and pinion a two-bearing overhung pinion mounting full-floating axle shafts a steel differential housing a front mounted removable one-piece carrier housing a conventional differential assembly or a Truetrac® limited slip differential assembly The trademark shows the company logo, and identifies the location of the manufacturing facility. CAUTION: Never mate a differential ring gear and pinion together that does not have the same matched set numbers. Always install a new matched set if discarding either the differential ring gear or the pinion. A corresponding number marked on the differential ring gear and pinion identifies them as a matched set. The manufacturer’s date identifies the gear set’s date of fabrication. The tooth combination identifies the number of teeth on the pinion and the number of teeth on the differential ring gear. A tooth combination of 41-11, for example, would indicate that the pinion has 11 teeth and the ring gear has 41 teeth that results in a 3.73:1 ratio. Dana Model S135 Full-Floating Rear Axle, Disassembled View

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1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100-00. 2. Remove the rear wheel and tire assembly. For additional information, refer to Section 204-00. 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. 5. Fill the axle with the specified quantity of the specified lubricant. For additional information, refer to the Specifications in this section. Item 2: Rear Disc Brake Caliper Removal Note 1. CAUTION: Do not allow the caliper to hang from the brake hose. Provide a suitable support. Position the rear disc brake caliper aside. For additional information, refer to Section 206-00. Item 7: Differential Pinion Shaft Removal Note 1. Move the differential pinion shaft out far enough to remove the U-washers. Replace the shaft and install the lock bolt finger tight when U-washers are removed. Item 8: U-washer Removal Note 1. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Remove the U-washers. 1. Push the axle shafts inboard. 2. Remove the U-washers. Item 10 and 11: Wheel Bearing Oil Seal and Axle Shaft Bearing Removal Note 1. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. For the 8.8 inch rear axle, use the special tools to remove the rear wheel bearing and wheel bearing oil seal. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. For the 9.75 inch and the 10.25 inch rear axles, use the special tools to remove the rear wheel bearing and wheel bearing oil seal. Item 11: Axle Shaft Bearing Installation Note 1. For the 8.8 inch and the 9.75 inch rear axles, use the special tools to install the rear axle wheel bearing. 2. For the 10.25 inch rear axle, use the special tools shown to install the rear axle wheel bearing. Item 10: Wheel Bearing Oil Seal Installation Note 1. Use the special tools shown to install the rear wheel bearing oil seal. Item 8: U-washer Installation Note 1. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers. 1. Position the two U-washers on the button end of the axle shafts. 2. Pull the axle shafts outward.

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WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the differential housing cover (4033). ? Drain the lubricant. For additional information, refer to Differential Housing Cover in this section. 4. Remove the brake calipers and discs. 5. Remove the differential pinion shaft (4211). 1. Remove and discard the differential pinion shaft lock bolt. 2. Remove the differential pinion shaft. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Remove the U-washers (4N237). 1. Push the axle shafts (4234) inboard. 2. Remove the U-washers. CAUTION: Do not damage the wheel bearing oil seal (1177). Remove the two axle shafts. Installation 1. Lubricate the lip of the wheel bearing oil seal. ? Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. Install the two axle shafts. CAUTION: Do not damage the wheel bearing oil seal. 3. Install the U-washers. 1. Position the two U-washers on the button ends of the axle shafts. 2. Pull the axle shafts outward. CAUTION: Do not damage the rubber O-rings in the U-washer grooves.

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Removal 1. Raise and support vehicle. Remove wheel, disc brake caliper, rotor, cotter pin, nut retainer, and axle hub nut. Remove hub-to-steering knuckle attaching bolts. Remove hub and rotor shield from steering knuckle. Remove axle shaft from axle tube. See the FRONT AXLE article in DRIVE AXLES. NOTE: DO NOT disconnect caliper unless service is needed. Support caliper with wire to prevent hose damage. 2. On models with front axle shift motor, remove outer axle shaft from right axle tube. Leave shift collar on intermediate shaft. On all models, remove caliper anchor plate from steering knuckle. Remove steering knuckle and ball joint cotter pins. Remove ball joint nuts. Strike steering knuckle at ball joint stud boss with a brass hammer to loosen knuckle from ball joint studs. Remove steering knuckle. See Fig. 2 . Installation 1. Position steering knuckle over ball joint studs and install nuts. Tighten nuts to specification. Install NEW cotter pins. Install caliper anchor plate and tighten bolts to specification. See TORQUE SPECIFICATIONS . Install axle shafts into axle tubes. 2. On vehicles with front axle shift motor, ensure shift collar is correctly positioned on intermediate axle shaft, install axle into shift collar inside axle tube. Ensure axle shaft is completely engaged with shift collar. 3. On all models, apply bearing grease to spindle hub bore in steering knuckle and install rotor shield and hub. Tighten spindle hub bolts. Install hub washer and nut. Tighten hub nut to specification. Install hub nut retainer and install NEW cotter pin. Install rotor, caliper and wheel. Lower vehicle.