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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 966 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear -- F150) >> 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 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Use 118 ml (4 oz.) of the specified friction modifier in the axle.
    Fig 1: Pre-lubricating Each Steel Clutch Plate
    G03878750Courtesy of FORD MOTOR CO.
  1. Pre-lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.
    2. CAUTION: Do not mix the differential clutch packs or selective shims from one side with the other.
    Fig 2: Assembling Differential Clutch Packs (Without Selective Shims) On Respective Differential Side Gears
    G03878751Courtesy of FORD MOTOR CO.
  2. Assemble the differential clutch packs (without the selective shims) on the respective differential side gears.
    3. CAUTION: Make sure the correct mandrel is used with the special tool.
    Fig 3: Installing Differential Clutch Pack And Differential Side Gear On The Gauge
    G03960230Courtesy 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 selective shim) on the gauge.
  4. Position the special tool hand-tight on top of the differential clutch pack.
    Fig 4: Positioning Special Tool Hand-Tight Of Differential Clutch Pack
    G03960231Courtesy 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
    G03960232Courtesy of FORD MOTOR CO.
  6. Install the nut of the gauge over the top and base stud.
    • Tighten to 6.7 Nm (60 lb-in).
    Fig 6: Installing Nut Of Gauge Over Top And Base Stud
    G03960233Courtesy of FORD MOTOR CO.
    7. NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit F5AZ-4947-BA.
    Fig 7: Inserting Feeler Gauge Between Tool And Differential Clutch Pack
    G03878756Courtesy 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. The reading will be the thickness of the new selective shim.
    SELECTIVE SHIMS

    Part Number Description
    E0AZ-4A324-G 0.025 in
    E0AZ-4A324-H 0.030 in
    E0AZ-4A324-C 0.035 in
    E0AZ-4A324-D 0.040 in
    E0AZ-4A324-F 0.045 in
  8. Remove the special tool from the clutch pack and differential side gear assembly.
  9. Install selective shims on the clutch pack and differential side gear assembly.
  10. Install the differential side gear in the differential case.
    Fig 8: Installing Differential Side Gear In Differential Case
    G03884253Courtesy of FORD MOTOR CO.
  11. Install the differential pinion gears with differential pinion gear thrust washers in the differential case.
    Fig 9: Installing Differential Pinion Gears With Differential Pinion Gear Thrust Washers In Differential Case
    G03878758Courtesy of FORD MOTOR CO.
  12. Using a soft-faced hammer, install the differential clutch spring.
    Fig 10: Using Soft-Faced Hammer To Install Differential Clutch Spring
    G03878759Courtesy of FORD MOTOR CO.
    13. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with threadlock prior to installation.
    Fig 11: Installing Differential Pinion Shaft And Installing New Differential Pinion Shaft Lock Bolt Finger-Tight
    G03878760Courtesy of FORD MOTOR CO.
  13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.
  14. Check the torque required to rotate one differential side gear.
    • Mount the differential assembly 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.
    Fig 12: Checking Torque Required To Rotate One Differential Side Gear
    G03960239Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the differential bearings on the differential case.
    Fig 13: Using Special Tool To Install Differential Bearings On Differential Case
    G03960240Courtesy of FORD MOTOR CO.
  16. Position the differential ring gear, the new anti-lock speed sensor ring and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and into the differential ring gear.
    17. NOTE: Apply stud and bearing mount to the differential ring gear bolts.
    Fig 14: Installing Differential Ring Gear Bolts
    G03878612Courtesy of FORD MOTOR CO.
  17. Install the differential ring gear bolts.
    • Tighten to 105 Nm (77 lb-ft).
  18. Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .
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