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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 778 (Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear) >> Disassembly And Assembly >> Differential Case and Ring Gear - Traction-Lok® >> Assembly

Differential Case and Ring Gear - Traction-Lok®: Assembly

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  1. Prelubricate each steel clutch plate and soak all friction plates with 118 ml (4 ounces) of friction modifier for at least 15 minutes.
    Fig 1: Prelubricating Each Steel Clutch Plate
    G03878750Courtesy of FORD MOTOR CO.
    2. NOTE: Do not mix the differential clutch packs or shims from one side with the other.
    NOTE: The Belleville spring is a dished plate.
    Fig 2: Assembling Differential Clutch Packs On Respective Differential Side Gears
    G03884593Courtesy of FORD MOTOR CO.
  2. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.
  3. Clamp the bolt head of the special tool in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.
    Fig 3: Installing Differential Clutch Pack And Differential Side Gear On Gauge
    G03884594Courtesy of FORD MOTOR CO.
  4. Position the special tool on top of the differential clutch pack.
    Fig 4: Positioning Special Tool On Top Of Differential Clutch Pack
    G03884595Courtesy of FORD MOTOR CO.
  5. Install the special tool over the disc and differential clutch pack.
    Fig 5: Installing Special Tool Over Disc And Differential Clutch Pack
    G03884596Courtesy of FORD MOTOR CO.
  6. Install the nut over the top and base stud.
    Fig 6: Installing Nut Over Top And Base Stud
    G03884597Courtesy of FORD MOTOR CO.
    7. NOTE: These shims are available as part of Clutch Pack Replacement Kit F75Z-4947-AA.
    Fig 7: Installing Clutch Shim
    G03884598Courtesy of FORD MOTOR CO.
  7. Use the Feeler Gauge and select the thickest blade that will enter between the tool and the differential clutch pack. This will be the thickness of the new clutch shim. Select the correct shim size, and remove the Traction-Lok Clutch Gauge.
    SHIM SIZE SPECIFICATION

    Part Number Description
    F75Z-4A324-DA 0.030 Inch
    F75Z-4A324-EA 0.035 Inch
    F75Z-4A324-FA 0.040 Inch
    F75Z-4A324-GA 0.045 Inch
    F75Z-4A324-HA 0.050 Inch
    F75Z-4A324-JA 0.055 Inch
    F75Z-4A324-KA 0.060
  8. Place the shim and Belleville spring on the differential clutch pack.
    • The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case.
      • Refer to the exploded view in the DESCRIPTION AND OPERATION .
        Fig 8: Placing Shim And Belleville Spring On Differential Clutch Pack
        G03884599Courtesy of FORD MOTOR CO.
  9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case.
    • Hold the upper clutch pack and side gear assembly in place to prevent it from falling out of the differential case.
      Fig 9: Inserting Differential Clutch Packs With Shims And Belleville Springs And Differential Side Gears Into Differential Case
      G03884600Courtesy of FORD MOTOR CO.
    10. NOTE: Apply a small amount of grease to the step plate bore.
    NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.
  10. Assemble the special tool to the differential case.
    1. Position the step plate in the bottom side gear bore.
    2. Position the nut in the top side gear bore and hold it in place.
    3. Install the hex-head screw and tighten it two turns after it contacts the bottom step plate.
      Fig 10: Assembling Special Tool To Differential Case
      G03884601Courtesy of FORD MOTOR CO.
    11. NOTE: Prelubricate both sides of the differential pinion thrust washers with rear axle lubricant.
    NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.
    Fig 11: Positioning Differential Pinion Gears And Differential Pinion Thrust Washers In Window Of Differential Case
    G03884602Courtesy of FORD MOTOR CO.
  11. Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth.
    12. WARNING: Keep fingers and hands away from pinion gears when rotating the differential case with the differential rotating tool.
    NOTE: It may be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.
    Fig 12: Inserting Special Tool Into Pinion Shaft Bore And Turn Differential Case
    G03884603Courtesy of FORD MOTOR CO.
  12. Insert the special tool into the pinion shaft bore and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears.
  13. Loosen the forcing screw and remove the step plate and nut from the side gear bores. Install the differential pinion shaft in the differential case.
    • Install a new differential pinion shaft lock bolt finger-tight.
      Fig 13: Installing Differential Pinion Shaft Lock Bolt Finger-Tight
      G03884604Courtesy of FORD MOTOR CO.
  14. Install new differential bearings, if removed.
    Fig 14: Installing Differential Bearings
    G03884374Courtesy of FORD MOTOR CO.
  15. Check the torque required to rotate one differential side gear.
    • Mount the differential case and the Traction-Lok Torque Tool Set in a vise.
    • The initial break-away torque, if original clutch plates are used, must be within specification. The rotating torque required to keep the differential side gear turning with new clutch plates can vary.
      Fig 15: Checking Torque Required To Rotate One Differential Side Gear
      G03884606Courtesy of FORD MOTOR CO.
    16. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
  16. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the bolts.
    • Apply sealer to the ring gear bolts before installation.
      Fig 16: Positioning Differential Ring Gear
      G03884376Courtesy of FORD MOTOR CO.
      Fig 17: Installing Ring Gear Bolts
      G03884377Courtesy of FORD MOTOR CO.
  17. Install the differential case. For additional information, refer to DIFFERENTIAL CASE .
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