Differential Case and Ring Gear - One Piece, 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.

Position the differential side gear thrust washers on the differential side gears.
- Use premium long-life grease to lubricate the differential side gear thrust washers and the differential side gear journals.
  
  Fig 1: Identifying Differential Thrust Washers & Differential Side Gears
  Courtesy of FORD MOTOR CO.
Position the differential side gears.

Fig 2: Identifying Differential Side Gears
Courtesy of FORD MOTOR CO.
Using premium long-life grease, assemble the differential pinion thrust washers and the differential pinion gears.

Fig 3: Using Premium Long-Life Grease On Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Engage the differential pinion gears opposite the differential side gears.

Fig 4: Identifying Differential Pinion Gears Opposite Differential Side Gears
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears to align the differential pinion shaft bore.

Fig 5: Identifying Differential Pinion Gears To Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.

CAUTION: If a new pinion shaft lock bolt is not available, use thread sealant and tighten to specification.

Insert the differential pinion shaft and install a new differential pinion shaft lock bolt.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 6: Locating Differential Pinion Shaft Lock Bolt
  Courtesy of FORD MOTOR CO.
Using the special tool, install the differential bearings.

Fig 7: Pressing Differential Bearings On Differential Case Using Special Tool
Courtesy of FORD MOTOR CO.
Install the differential ring gear.
1. Place the differential ring gear on the differential case.
2. Hand start 3 bolts to align the holes in the differential ring gear and the differential case.
3. Place the differential case and differential ring gear on the press bed with the ring gear facing down.
4. Press the ring gear into place.
  
  Fig 8: Pressing Differential Ring Gear Into Place
  Courtesy of FORD MOTOR CO.
Using a thread sealant, install the ring gear bolts and tighten.
- Tighten to 150 Nm (111 lb-ft).
  
  Fig 9: Identifying 12 Differential Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
Install the differential case. For additional information, refer to DIFFERENTIAL CASE .