Differential Case and Ring Gear - Conventional: Assembly

WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Use a vise with brass jaws or wood blocks.

Place the differential case in a vise.

NOTE: The best way to assemble the differential side gears and the differential pinion gears is to lubricate all parts with the specified rear axle lubricant.

Fig 1: Identifying Differential Side Gears

Courtesy of FORD MOTOR CO.

Lubricate and assemble both differential side gears and differential side gear thrust washers. Hold them in place. Then, lubricate and assemble the differential pinion gears with the differential pinion gear thrust washers to hold the differential side gears in place.

NOTE: Rotate the differential side gears until the holes of the differential pinion gear thrust washers and the differential pinion gears line up with the holes of the differential case. If the differential pinion gears will not rotate by hand, install one of the axle shafts into the spline of the differential side gear and use a pipe wrench to turn the axle shaft.

Using a suitable tool, line up the holes with those of the differential case.
Position the differential pinion shaft. Align the lockpin hole in the differential pinion shaft with the lockpin hole in the differential case.
Assemble the differential pinion shaft lockpin. Peen the metal of the differential case over the differential pinion shaft lockpin in 2 places, 180 degrees apart, to lock it in place. Note the location of the slot in the differential pinion shaft lockpin and peen it 90 degrees apart.

Fig 2: Peening Metal Of Differential Case Over
Courtesy of FORD MOTOR CO.

NOTE: Apply Threadlock and Sealer to the 2 new differential ring gear bolts.

NOTE: If removed, install the anti-lock speed sensor ring.

Fig 3: Locating Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Start 2 bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and the differential case align.
Press the differential ring gear on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.

Fig 4: Pressing Ring Gear And Anti-Lock Speed Sensor Ring Onto Differential Case
Courtesy of FORD MOTOR CO.
Apply threadlock and install the 10 remaining bolts alternately and evenly.
- Tighten to 298 Nm (220 lb-ft).
- Use Threadlock and Sealer TA-25 or equivalent meeting Ford specification WSK-M2G351-A5.
  
  Fig 5: Identifying Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
Using the special tool, install the differential bearing and shim on the LH side of the differential case.

Fig 6: Identifying Special Tool For Differential Bearing Installation
Courtesy of FORD MOTOR CO.
Using the special tools, install the differential bearing.
1. Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
2. Using the special tool, drive the differential bearing onto the hub.
  
  Fig 7: Identifying Special Tool
  Courtesy of FORD MOTOR CO.
Assemble the new differential bearing cups to the new differential bearings.
Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .