LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1800 (Rear Drive Axle/Differential - Ford 9.75-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.
  1. Lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.
    2. Fig 1: Identifying Friction Plates & Friction Modifier
    GF0003104Courtesy of FORD MOTOR CO.
    NOTE: Do not mix the differential clutch packs or selective shims from one side with the other.
    NOTE: The Belleville spring is a dished plate.
  2. Assemble the differential clutch packs (without the selective shims and Belleville springs) on their respective differential side gears.
    3. Fig 2: Identifying Differential Clutch Packs
    GF0003177Courtesy of FORD MOTOR CO.
  3. Clamp the bolt head of the special tool in a vise. Install the differential clutch pack and the differential side gear (without the selective shim or the Belleville spring) on the special tool.
    4. Fig 3: Clamping Bolt Head Of Special Tool In Vise
    GF0003178Courtesy of FORD MOTOR CO.
  4. Position the special tool on top of the differential clutch pack.
    5. Fig 4: Identifying Special Tool On Differential Clutch Pack
    GF0003179Courtesy of FORD MOTOR CO.
  5. Install the special tool over the disc and differential clutch pack.
    6. Fig 5: Identifying Special Tool On Differential Clutch Pack
    GF0003180Courtesy of FORD MOTOR CO.
  6. Install the nut over the top and base stud.
    • Tighten to 7 Nm (62 lb-in).
    7. Fig 6: Locating Differential Clutch Pack Nut
    GF0003109Courtesy of FORD MOTOR CO.
  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.
    8. Fig 7: Locating Thickest Blade
    GF0003110Courtesy of FORD MOTOR CO.
  8. Place the selective shim and Belleville spring on the differential clutch pack.
    • The dished or concave side of the Belleville spring must face up against the thrust face of the differential case.
    9. Fig 8: Locating Selective Shim
    GF0003181Courtesy of FORD MOTOR CO.
  9. Install the differential side gears with the differential clutch packs, selective shims and Belleville spring into the differential case.
    • Hold the differential side gear assembly in place to prevent it from falling out of the differential case.
    10. Fig 9: Identifying Differential Side Gear
    GF0003182Courtesy of FORD MOTOR CO.
    NOTE: Apply a small amount of grease to the step plate bore.
    NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.
  10. Assemble the special tool to the differential case.
    • Position the special tool in the bottom differential side gear.
    • Position the special tool in the top differential side gear and hold it in place.
    • Install the special tool and tighten it 2 turns after it contacts the bottom step plate.
    11. Fig 10: Identifying Special Tool To Differential Case
    GF0003183Courtesy of FORD MOTOR CO.
    NOTE: Lubricate both sides of the differential pinion gear thrust washers with axle lubricant.
    NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.
  11. Position the differential pinion gears and differential pinion gear thrust washers in the window of the differential case so they mesh with the differential side gear teeth.
    12. Fig 11: Locating Differential Pinion Gears
    GF0003184Courtesy of FORD MOTOR CO.
    NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.
  12. Insert the special tool into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion shaft mating holes are lined up exactly with the holes in the differential pinion gears.
    13. Fig 12: Inserting Special Tool Into Pinion Shaft Bore
    GF0003185Courtesy of FORD MOTOR CO.
  13. Remove the special tools.
    14. NOTE: If a new differential pinion shaft lock bolt is unavailable, coat the threads of the original differential pinion shaft lock bolt with threadlock prior to installation.
  14. Install the differential pinion shaft, then a new differential pinion shaft lock bolt finger-tight.
    15. Fig 13: Locating Differential Pinion Shaft Lock Bolt
    GF0003186Courtesy of FORD MOTOR CO.
  15. Install the 2 new differential bearings.
    16. Fig 14: Pressing Differential Bearings On Differential Case Using Special Tool
    G03884442Courtesy of FORD MOTOR CO.
  16. Check the torque required to rotate one differential side gear.
    • Install the special tools with the 1/2-inch drive hole as shown.
    • The initial break-away torque, if original clutch plates are used, must be at least the minimum specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.
    17. Fig 15: Checking Torque Using Special Tools
    GF0003187Courtesy of FORD MOTOR CO.
  17. Install the differential ring gear and, if removed, a new anti-lock ring.
    18. Fig 16: Locating Anti-Lock Ring
    GF0003161Courtesy of FORD MOTOR CO.
    NOTE: Apply stud and bearing mount to the differential ring gear bolts.
  18. Install the new 12 differential ring gear bolts.
    • Tighten to 150 Nm (111 lb-ft).
    19. Fig 17: Identifying 12 Differential Ring Gear Bolts
    GF0003136Courtesy of FORD MOTOR CO.
  19. Install the differential carrier assembly in the axle housing.
    20. Fig 18: View Of Differential Assembly In Axle Housing
    GF0000841Courtesy of FORD MOTOR CO.
    NOTE: Install the differential bearing shims with the chamfer facing outboard.
  20. Install a differential bearing shim on the LH side.
    21. Fig 19: Identifying Differential Bearing Shim On Left Side
    GF0003162Courtesy of FORD MOTOR CO.
    NOTE: The differential bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.
  21. Install the LH differential bearing cap and loosely install the 2 differential bearing cap bolts.
    22. Fig 20: Identifying LH Differential Bearing Cap And Bolts
    GF0000842Courtesy of FORD MOTOR CO.
    NOTE: Install the differential bearing shims with the chamfer facing outboard.
  22. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.
    23. Fig 21: Identifying Differential Bearing Shim
    GF0000843Courtesy of FORD MOTOR CO.
  23. Install the RH side differential bearing cap and tighten the 2 LH side and 2 RH side differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    24. Fig 22: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  24. Rotate the differential assembly to make sure it rotates freely.
    25. Fig 23: Rotating Differential Assembly
    GF0000844Courtesy of FORD MOTOR CO.
    NOTE: If ring gear backlash is within specification, go to Step 30.
    NOTE: Specification shown is the maximum ring gear backlash allowable.
  25. Using the special tools, measure ring gear backlash.
    • Turn the ring gear without turning the pinion gear and record the measurement.
    26. Fig 24: Measuring Ring Gear Backlash Using Special Tools
    G03884451Courtesy of FORD MOTOR CO.
    NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.
  26. To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
    • If ring gear backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
      Backlash Change Required Thickness Change Required
      mm In mm In
      0.025 0.001 0.050 0.002
      0.050 0.002 0.050 0.002
      0.076 0.003 0.101 0.004
      0.101 0.004 0.152 0.006
      0.127 0.005 0.152 0.006
      0.152 0.006 0.203 0.008
      0.177 0.007 0.254 0.010
      0.203 0.008 0.254 0.010
      0.228 0.009 0.304 0.012
      0.254 0.010 0.355 0.014
      0.279 0.011 0.355 0.014
      0.304 0.012 0.406 0.016
      0.330 0.013 0.457 0.018
      0.335 0.014 0.457 0.018
      0.381 0.015 0.508 0.020
    27. Fig 25: Identifying Differential Bearing Shims
    G03884521Courtesy of FORD MOTOR CO.
    NOTE: The bearing caps must be removed before differential bearing shims can be installed.
  27. To decrease ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim of the same thickness change.
    28. Fig 26: Identifying Differential Bearing Shims
    G03884521Courtesy of FORD MOTOR CO.
  28. Rotate the differential assembly several times to make sure the differential bearings are seated.
    29. Fig 27: Rotating Differential Assembly
    GF0000870Courtesy of FORD MOTOR CO.
  29. Using the special tools, recheck the ring gear backlash.
    30. Fig 28: Measuring Ring Gear Backlash Using Special Tools
    G03884451Courtesy of FORD MOTOR CO.
  30. Remove the 4 differential bearing cap bolts and the 2 differential bearing caps.
    31. Fig 29: Locating Differential Bearing Cap Bolts
    GF0003144Courtesy of FORD MOTOR CO.
    NOTE: Install the differential bearing shims with the chamfer facing outboard.
    NOTE: To establish differential bearing preload, increase both left and right differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.
  31. Using the special tool, install the differential bearing shims.
    32. Fig 30: Identifying Special Tool To Differential Bearing Shims
    GF0003145Courtesy of FORD MOTOR CO.
  32. Install the differential bearing caps and differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    33. Fig 31: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  33. Apply high contrast hypoid gear marking compound and rotate the differential assembly 5 complete revolutions.
  34. Verify an acceptable pattern check.
    35. CAUTION: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.
  35. Clean the gasket mating surface of the axle and the differential housing cover.
  36. Install the axle shafts. For additional information, refer to Axle Shaft  in this article.
scientia non olet · About LEMON Manuals