Differential Case and Ring Gear - Traction-Lok® : Assembly

1. Soak the clutch packs for 20 minutes in friction modifier before assembly.
Fig 1: Rear Axle Disc And Plate Kit
Courtesy of FORD MOTOR CO.
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 2: Cutaway View Of Side Gear Ring, Rear Axle Disc & Plate Kit, Side Gear & Flange Half Of Differential Case
Courtesy of FORD MOTOR CO.
CAUTION: After assembly, make sure that the side gear splines engage the clutch pack splines and the differential side gear is fully seated.
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.

   Item	Part Number	Description
   1	4204	Differential case (flange half)
   2	-	Clutch plate (part of 4880)
   3	-	Dished clutch disc (part of 4880)
   4	-	Side gear ring (part of 4880)
   5	4236	Differential side gear

Fig 3: Cutaway View Of Side Gear Ring, Rear Axle Disc & Plate Kit, Side Gear & Flange Half Of Differential Case
Courtesy of FORD MOTOR CO.
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.
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.

   Item	Part Number	Description
   1	4204	Differential case (button half)
   2	-	Clutch plate (part of 4880)
   3	-	Dished clutch disc (part of 4880)
   4	-	Side gear ring (part of 4880)
   5	4236	Differential side gear

Fig 4: Differential Pinion Shaft & Differential Pinion Gears In Button Half
Courtesy of FORD MOTOR CO.
CAUTION: Align the match marks made during disassembly.
5. Place the differential pinion shaft and differential pinion gears in the button half of the differential case.
Fig 5: Differential Pinion Shaft & Differential Pinion Gears In Flange Half
Courtesy of FORD MOTOR CO.
CAUTION: Align the match marks made during disassembly.
6. Install the other differential pinion shaft and differential pinion gears in the flange half of the differential case.
Fig 6: Differential Case Bolts With Torque Specifications
Courtesy of FORD MOTOR CO.
CAUTION: Align the match marks made during disassembly.
CAUTION: The bolts must be clean and dry.
7. Assemble the differential case.
   1. Place the button half of the differential case onto the flange half of the differential case assembly.

   Install the bolts. Turn each one in a few threads.

Tighten the bolts evenly and alternately.

• Tighten to 129 Nm (95 lb-ft).
• 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.
• Install the differential case. For additional information, refer to Differential Case .