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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1801 (Rear Drive Axle/Differential - Ford 10.25-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.
  2. Assemble the differential clutch packs (without the selective shims and Belleville springs) on their respective differential side gears.
    3. Fig 2: Assembling Differential Clutch Packs On Respective Differential Side Gears
    GF0003177Courtesy of FORD MOTOR CO.
  3. Clamp the special tool in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.
    4. Fig 3: Clamping Special Tool In Vise
    GF0003205Courtesy of FORD MOTOR CO.
  4. Position the special tool on top of the differential clutch pack.
    5. Fig 4: Positioning Special Tool On Top Of 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 Disc And 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.
    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-H 0.030 in
    E0AZ-4A324-C 0.035 in
    E0AZ-4A324-D 0.040 in
    E0AZ-4A324-F 0.045 in
    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.
    NOTE: Hold the differential side gear assembly in place to prevent it from falling out of the differential case.
  9. Install the differential side gears with the differential clutch packs, selective shims and Belleville spring into the differential case.
    10. Fig 9: Identifying Differential Side Gear Assembly
    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 forcing screw, nut and step plate to the differential case.
    • Position the step plate in the bottom side gear bore.
    • Position the nut in the top side gear bore and hold it in place.
    • Install the hex-head screw and tighten it 2 turns after it contacts the bottom step plate.
    11. Fig 10: Identifying Special Tools
    GF0003206Courtesy 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: Positioning Differential Pinion Gears And Differential Pinion Gear
    GF0003184Courtesy of FORD MOTOR CO.
    NOTE: It may be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.
  12. Inserting the special tool into the pinion shaft bore, 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 mating shaft holes are lined up exactly with the holes in the differential pinion gears.
    13. Fig 12: Inserting Special Tool Into Pinion Shaft Bore And Turning Differential Case
    GF0003207Courtesy 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. If removed, install new LH and RH 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 within specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.
    17. Fig 15: Checking Torque Required To Rotate One Differential Side Gear
    GF0003208Courtesy of FORD MOTOR CO.
    NOTE: If removed, press a new anti-lock ring on the differential case with the ring gear.
  17. Install the differential ring gear.
    • Position the differential ring gear on the differential case.
    • Hand start 3 new ring gear bolts to align the holes in the differential ring gear and the differential case flange.
    • Place the differential assembly and differential ring gear on the press plate blocks with the ring gear facing down.
    • Press the differential ring gear into place.
    18. Fig 16: Pressing Differential Ring Gear Into Place
    G03884443Courtesy of FORD MOTOR CO.
  18. Install the 12 new differential ring gear bolts.
    • Tighten the 12 bolts to 150 Nm (111 lb-ft).
    19. Fig 17: Identifying 12 Differential Ring Gear Bolts
    GF0003136Courtesy of FORD MOTOR CO.
  19. Place the differential assembly in the axle housing.
    20. Fig 18: Positioning Differential Assembly In Axle Housing
    GF0000841Courtesy of FORD MOTOR CO.
    NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.
  20. Install a differential bearing shim on the left side.
    21. Fig 19: Locating Differential Bearing Shim
    GF0003209Courtesy of FORD MOTOR CO.
    NOTE: Apply pressure toward the left side to make sure the left differential bearing cup is seated.
  21. Install the left 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.
  22. Install progressively larger differential bearing shims on the right side until the largest differential bearing shim selected can be inserted by hand.
    23. Fig 21: Installing Progressively Larger Differential Bearing Shims
    GF0000869Courtesy of FORD MOTOR CO.
  23. Install the right side differential bearing cap with 2 bolts and tighten the 4 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
    GF0000870Courtesy 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. 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 on the left and a thinner differential bearing shim on the right.
    28. Fig 25: 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 26: Rotating Differential Assembly
    GF0000870Courtesy of FORD MOTOR CO.
  29. Using the special tools, recheck the ring gear backlash.
    30. Fig 27: 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 28: Locating Differential Bearing Cap Bolts & Differential Bearing Caps
    GF0003144Courtesy of FORD MOTOR CO.
    NOTE: Differential bearing shims are to be installed 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 2 differential bearing shims.
    32. Fig 29: Identifying Special Tool On Differential Bearing Shims
    GF0003145Courtesy of FORD MOTOR CO.
  32. Install the 2 differential bearing caps and the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    33. Fig 30: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  33. Using the special tools, recheck the backlash.
    34. Fig 31: Measuring Ring Gear Backlash Using Special Tools
    G03884451Courtesy of FORD MOTOR CO.
  34. Install the axle shafts. For additional information, refer to Axle Shaft  in this article.
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