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

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: 118 ml (4 oz.) of the Additive Friction Modifier must be used in the axle.

Fig 1: Identifying Friction Plates & Friction Modifier

Courtesy of FORD MOTOR CO.

Using the modifier, lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes.

CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the other.

Fig 2: Assembling Differential Clutch Packs (Without Selective Shims) On Differential Side Gears

Courtesy of FORD MOTOR CO.

Assemble the differential clutch packs (without the shims) on their respective differential side gear.
Install the differential side gear assemblies in the differential case.

Fig 3: Installing Differential Side Gear Assemblies In Differential Case
Courtesy of FORD MOTOR CO.
Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case.

Fig 4: Installing Differential Pinion Gear And Thrust Washer Assemblies In Differential Case
Courtesy of FORD MOTOR CO.
Using a soft-faced hammer, install the differential clutch spring.

Fig 5: Installing Differential Clutch Spring
Courtesy of FORD MOTOR CO.
Install the differential pinion shaft and install a new bolt finger-tight.

Fig 6: Installing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
- If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.
  
  Fig 7: Checking Differential Side Gear Rotating Torque
  Courtesy of FORD MOTOR CO.
Using the special tool, install the differential bearings.

Fig 8: Installing Differential Bearings On Differential Case
Courtesy of FORD MOTOR CO.
Position the differential ring gear and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.

Fig 9: Pressing Differential Ring Gear Onto Differential Case
Courtesy of FORD MOTOR CO.

NOTE: Clean bolt threads to make sure the bolts are free of foreign material.

Apply stud and bearing mount to the differential ring gear bolt threads and install the bolts.
- Install new bolts.
  - Tighten to 114 Nm (84 lb-ft).
    
    Fig 10: Installing Differential Ring Gear Bolts
    Courtesy of FORD MOTOR CO.
Install the differential assembly. For additional information, refer to DIFFERENTIAL CASE .

WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .

If equipped with fire suppression system, repower the system.