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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1539 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> 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 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Soak the clutch packs for 20 minutes in friction modifier before assembly.
  2. Place the side gear ring on the pinion flange. Coat the rear axle disc and plate kit with lubricant and place it on the side gear ring.
    • Use rear axle lubricant or friction modifier.
      Fig 1: Locating Friction Modifier
      G04643659Courtesy of FORD MOTOR CO.
    3. CAUTION: After assembly, make sure that the side gear splines engage the clutch pack splines and the differential side gear is fully seated.
    Fig 2: Locating Side Gear Ring, Rear Axle Disc And Plate Kit
    G04643660Courtesy of FORD MOTOR CO.
  3. Install the side gear ring, the rear axle disc and plate kit and the side gear in the flange half of the differential case.
    4. NOTE: For vehicles operating at close to their GVW rating, typically emergency vehicles and vehicles equipped with a fifth wheel, there may be circumstances of continuing chatter/bumping in turns despite the installation of new parts and lubricant. In cases such as this, it is permissible to reassemble the rear axle disc and plate kit with the clutch disc adjacent to the differential side gear ring, resulting in 2 clutch plates together. This results in 3 friction surfaces instead of the normal 5, lowering the torque to rotate the wheel by 40 percent.
    Fig 3: Locating Side Gear Ring, Rear Axle Disc And Plate Kit
    G04643661Courtesy of FORD MOTOR CO.
  4. Align the clutch pressure plate lugs, and install the side gear ring, the clutch pack and differential side gear in the button half of the differential case.
    5. CAUTION: Align the match marks made during disassembly.
    Fig 4: Locating Differential Pinion Shaft And Differential Pinion Gears
    G04643662Courtesy of FORD MOTOR CO.
  5. Place the differential pinion shaft and differential pinion gears in the button half of the differential case.
    6. CAUTION: Align the match marks made during disassembly.
    Fig 5: Locating Differential Pinion Shaft And Differential Pinion Gears
    G04643663Courtesy of FORD MOTOR CO.
  6. Install the other differential pinion shaft and differential pinion gears in the flange half of the differential case.
    7. CAUTION: Align the match marks made during disassembly.
    Fig 6: Identifying Button Half Of Differential Case
    G04643664Courtesy of FORD MOTOR CO.
  7. Assemble the differential case.
    1. Place the button half of the differential case onto the flange half of the differential case assembly.
      2. CAUTION: The bolts must be clean and dry.
    2. Install the bolts. Turn each one in a few threads.
    3. Tighten the bolts evenly and alternately.
      • Tighten to 129 Nm (95 lb-ft).
  8. If assembled correctly, each differential pinion shaft will fit tight on its ramp. Clearance between the differential pinion shaft and the ramp must not be more than 0.254 mm (0.010 inch) and it must be equal at all 4 ends of the differential pinion shafts.
  9. Install the differential case. For additional information, refer to DIFFERENTIAL CASE .
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