Differential Case: Assembly
WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Place the differential case into a vise with soft jaws.
- Apply axle and wheel bearing grease to the following.
- The differential side gear thrust washers.
- The differential side gear hubs and thrust faces.
- The differential pinion thrust washers.
- The differential pinion gears.
- Assemble the gears and their respective washers.
- Lubricate the gears with lubricant, then install them into the differential case.
- Install and hold the differential side gears and thrust washers in the differential case. Then, install the differential pinion gears and thrust washers and rotate them until the pinion shaft bore in the case and gears align.
- If hand rotation of the gears is not possible, install an axle shaft into the differential side gear and turn the shaft with a pipe wrench.
- If necessary, use a drift to align the pinion shaft bores.
- Install and hold the differential side gears and thrust washers in the differential case. Then, install the differential pinion gears and thrust washers and rotate them until the pinion shaft bore in the case and gears align.
- Install the differential pinion shaft, aligning the lock pin bore in the differential case and the pinion shaft.
- Install the differential pinion shaft lock pin.
- Peen the differential case metal over the lock pin, in 2 places, 90 degrees from the slot in the lock pin.
- Assemble the ring gear to the differential case and alternately and evenly tighten the new bolts.
- Tighten to 183 Nm (135 lb-ft).
- Install the differential bearings only after determining the appropriate amount of differential bearing shims to install. For additional information, refer to AXLE .