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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1799 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear -- F150 & Mark LT) >> 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 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Use 118 ml (4 oz) of the specified friction modifier in the axle.
  1. Pre-lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.
    2. Fig 1: Soaking All Friction Plates
    GF0003104Courtesy of FORD MOTOR CO.
    NOTE: Do not mix the differential clutch packs or selective shims from one side with the other.
  2. Assemble the differential clutch packs (without the selective shims) on the respective differential side gears.
    3. Fig 2: Identifying Differential Clutch Packs And Differential Side Gears
    GF0003105Courtesy of FORD MOTOR CO.
    NOTE: Make sure the correct mandrel is used with the special tool.
  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. Fig 3: Installing Differential Clutch Pack And Differential Side Gear On The Gauge
    GF0003106Courtesy of FORD MOTOR CO.
  4. Position the special tool hand-tight on top of the differential clutch pack.
    5. Fig 4: Positioning Special Tool Hand-Tight On Top Of Differential Clutch Pack
    GF0003107Courtesy of FORD MOTOR CO.
  5. Install the special tool over the disc and differential clutch pack.
    6. Fig 5: Installing Special Tool Over Disc And Differential Clutch Pack
    GF0003108Courtesy 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).
    7. Fig 6: Installing Nut Over Top And Base Stud
    GF0003109Courtesy of FORD MOTOR CO.
    NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit F5AZ-4947-BA.
  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. Fig 7: Identifying Special Tool In Clutch Pack
    GF0003110Courtesy of FORD MOTOR CO.
  9. Install selective shims on the clutch pack and differential side gear assembly.
  10. Install the differential side gear in the differential case.
    11. Fig 8: Identifying Differential Side Gears
    GF0000881Courtesy of FORD MOTOR CO.
  11. Install the differential pinion gears with differential pinion gear thrust washers in the differential case.
    12. Fig 9: Identifying Differential Pinion Gears
    GF0000882Courtesy of FORD MOTOR CO.
  12. Using a soft-faced hammer, install the differential clutch spring.
    13. Fig 10: Install The Differential Clutch Spring
    GF0000883Courtesy of FORD MOTOR CO.
    NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with threadlock prior to installation.
  13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.
    14. Fig 11: Install A New Differential Pinion Shaft Lock Bolt
    GF0000884Courtesy of FORD MOTOR CO.
  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.
    15. Fig 12: Checking Rotational Torque Using Special Tool (205-022)
    GF0003111Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the 2 differential bearings on the differential case.
    16. Fig 13: Using Special Tool (205-010) To Install Differential Bearings
    GF0003112Courtesy 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 new bolts through the holes in the differential case and into the differential ring gear.
  17. Install the 8 remaining new differential ring gear bolts.
    • Tighten to 105 Nm (77 lb-ft).
      • Fig 14: Identifying Differential Ring Gear Bolts
      G03878612Courtesy of FORD MOTOR CO.
  18. Install the differential carrier. For additional information, refer to Differential Carrier  in this article.
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