Differential Case and Ring Gear-Conventional: Assembly

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Using rear axle lubricant to lubricate the differential side gear thrust washer and the differential side gear journals.
- Position the differential side gear thrust washer on the differential side gear.
  
  Fig 1: Positioning Differential Side Gear Thrust Washer On Differential Side Gear
  Courtesy of FORD MOTOR CO.
Position the differential side gear.

Fig 2: Positioning Differential Side Gear
Courtesy of FORD MOTOR CO.
Using rear axle lubricant, lubricate the differential side gear thrust washer and the differential pinion gear and assemble.

Fig 3: Lubricating Differential Side Gear Thrust Washer
Courtesy of FORD MOTOR CO.
Engage the differential pinion gear opposite the differential side gear.

Fig 4: Engaging Differential Pinion Gear Opposite Differential Side Gear
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gear to align with the differential pinion shaft bore.

Fig 5: Rotating Differential Pinion Gear To Align With Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Insert the differential pinion shaft.
- Align the hole in the differential pinion shaft with the hole in the differential case.
  
  Fig 6: Identifying Hole In Differential Pinion Shaft With Hole In Differential Case
  Courtesy of FORD MOTOR CO.

NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with threadlock prior to installation.

Fig 7: Installing New Differential Pinion Shaft Lock Bolt And Tighten Finger-Tight

Courtesy of FORD MOTOR CO.

Install a new differential pinion shaft lock bolt and tighten finger-tight.
Using the special tool, install the new differential bearings on the differential case.

Fig 8: Installing New Differential Bearings On Differential Case Using Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.

Fig 9: Pressing New Anti-Lock Speed Sensor Ring And Ring Gear On Differential Case

Courtesy of FORD MOTOR CO.

Press the new anti-lock speed sensor ring and the ring gear on the differential case.

NOTE: Apply stud and bearing mount to ring gear bolts.

Fig 10: Installing Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Install the ring gear bolts.
Install the differential case. Refer to DIFFERENTIAL CASE .