Differential Case and Ring Gear - Conventional: Assembly

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Position the differential side gear thrust washers on the differential side gears.
- Lubricate the differential side gear thrust washers and the differential side gear journals with rear axle lubricant.
Fig 1: Positioning Differential Side Gear Thrust Washers On Differential Side Gears
Courtesy of FORD MOTOR CO.
Position the differential side gears.

Fig 2: Positioning Differential Side Gears
Courtesy of FORD MOTOR CO.
Assemble the differential pinion thrust washers and the differential pinion gears.
- Lubricate the pinion gears and the pinion thrust washers with rear axle lubricant.
Fig 3: Identifying Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Engage the differential pinion gears opposite the differential side gears.

Fig 4: Engaging Differential Pinion Gears Opposite Differential Side Gears
Courtesy of FORD MOTOR CO.
Using the special tool, install the differential bearings.

Fig 5: Installing Differential Bearings
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears to align the differential pinion shaft bore.

Fig 6: Rotating Differential Pinion Gears To Align Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.

Fig 7: Installing Differential Pinion Shaft Lock Bolt
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 8: Pressing 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.
Install the bolts and tighten.
- Apply sealer to the ring gear bolts.
Fig 9: Installing Ring Gear Bolts
Courtesy of FORD MOTOR CO.
Install the differential case. For additional information, refer to DIFFERENTIAL CASE .