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Home >> Ford >> 1996 >> Aerostar Van Window >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Drive Axle - 7.5" Ring Gear Differentials >> Overhaul >> Differential Assembly >> Final Assembly

Final Assembly

  1. Install axle shaft, using care not to damage oil seal. Engage axle shaft with splines and push firmly inward. Install "C" locks, and then pull axle shaft outward to seat "C" locks in counterbore of side gear. Install pinion shaft through differential case and pinion gears. Align pinion shaft hole with pinion shaft lock bolt hole. Install and tighten pinion shaft lock bolt to specification. See TORQUE SPECIFICATIONS  .
    NOTE: Aerostar uses a plastic housing cover. Housing cover and retaining bolts must be replaced. DO NOT  reuse housing cover or retaining bolts.
  2. Ensure all sealing surfaces are clean. Apply a 3/16" diameter bead of silicone sealant on housing cover sealing surface on inside area of bolt holes.
  3. Install housing cover and retaining cover bolts. Use NEW  retaining bolts and cover. Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS  .
  4. Ensure reference mark on drive shaft flanges are aligned. Fill axle with lubricant and install filler plug. To install remaining components, reverse removal procedure.
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