LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 315 (Drive Axle/Differential - 8.8-Inch Ring Gear) >> Disassembly And Assembly >> Differential Case and Ring Gear - Traction-Lok >> Assembly

Differential Case and Ring Gear - Traction-Lok: Assembly

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: 118 ml (4 oz) of the specified Additive Friction Modifier must be used in the axle.
    Fig 1: Prelubricating Each Steel Clutch Plate And Soak All Friction Plates With Additive Friction Modifier C8Az-19B546-A
    G01440546Courtesy of FORD MOTOR CO.
  1. Prelubricate each steel clutch plate and soak all friction plates with Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.
    2. CAUTION: Do not mix the differential clutch packs or shims from one side with the other.
    Fig 2: Assembling Differential Clutch Packs
    G01440547Courtesy of FORD MOTOR CO.
  2. Assemble the differential clutch packs (without the shims) on the respective differential side gears.
    3. CAUTION: Select the correct mandrel to use with the Traction-Lok Differential Gauge.
    Fig 3: Installing Differential Clutch Pack
    G01440548Courtesy of FORD MOTOR CO.
  3. Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge.
  4. Position the special tool hand-tight on top of the differential clutch pack.
    Fig 4: Positioning Special Tool
    G01440549Courtesy of FORD MOTOR CO.
  5. Install the special tool over the disc and differential clutch pack.
    Fig 5: Installing Special Tool Over Disc
    G01440550Courtesy of FORD MOTOR CO.
  6. Install the nut of the gauge over the top and base stud.
    Fig 6: Installing Nut
    G01440551Courtesy of FORD MOTOR CO.
  7. Select the thickest blade of a suitable feeler gauge that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.
    Fig 7: Selective Shims Specification Chart
    G01440552Courtesy of FORD MOTOR CO.
    Fig 8: Identifying Feeler Gauge Inserting Location
    G01440553Courtesy of FORD MOTOR CO.
  8. Remove the special tool from the clutch pack and side gear assembly.
  9. Install shims on the clutch pack and side gear assembly.
  10. Install the differential side gear in the differential case.
    Fig 9: Installing Differential Side Gear In Differential Case
    G01440554Courtesy of FORD MOTOR CO.
  11. Install the differential pinion gears with differential pinion thrust washers in the differential case.
    Fig 10: Installing Differential Pinion Gears With Differential Pinion Thrust Washers In Differential Case
    G01440555Courtesy of FORD MOTOR CO.
  12. Install the differential clutch spring, using a soft-faced hammer.
    Fig 11: Installing Differential Clutch Spring
    G01440556Courtesy of FORD MOTOR CO.
  13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.
    Fig 12: Installing Differential Pinion Shaft Lock Bolt
    G01440557Courtesy of FORD MOTOR CO.
  14. Using the special tool, install the differential bearing on the differential case. Repeat for the other side.
    Fig 13: Installing Differential Bearing On Differential Case
    G01440558Courtesy of FORD MOTOR CO.
  15. Install the anti-lock speed sensor ring by aligning the tab on the anti-lock speed sensor ring with the slot on the differential case.
    • Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly.
    Fig 14: Installing Anti-Lock Speed Sensor Ring
    G01440559Courtesy of FORD MOTOR CO.
    16. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
    Fig 15: Pressing Anti-Lock Speed Sensor Ring And Ring Gear On Differential Case
    G01440560Courtesy of FORD MOTOR CO.
  16. Press the new anti-lock speed sensor ring and the ring gear on the differential case.
  17. Install the ring gear bolts.
    • Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts.
    Fig 16: Installing Ring Gear Bolts
    G01440561Courtesy of FORD MOTOR CO.
  18. Check the torque required to rotate one differential side gear.
    • Mount the differential case and special tool in a vise.
    • The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.
    • For additional information, refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
    Fig 17: Rotating Differential Side Gear
    G01440562Courtesy of FORD MOTOR CO.
  19. Install the differential case. For additional information, refer to DIFFERENTIAL CASE .
scientia non olet · About LEMON Manuals