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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1887 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- F250-F350 Super Duty) >> Disassembly And Assembly >> Differential Case and Ring Gear - One-Piece, Traction-Lok® >> Assembly

Differential Case and Ring Gear - One-Piece, Traction-Lok®: Assembly

WARNING: This page is about a different car, the 2007 Ford Pickup and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Soaking All Friction Plates
GF0003104Courtesy of FORD MOTOR CO.
  1. Prelubricate each steel clutch plate and soak all friction plates in friction modifier.
    2. Fig 2: Exploded View Of Differential Side Gears, Clutch Plates & Clutch Discs
    GF0006542Courtesy of FORD MOTOR CO.
    NOTE: Do not mix the differential clutch packs or shims from one side with the other.
    NOTE: The Belleville spring is a dished plate.
  2. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.
    3. Fig 3: Differential Clutch Pack & Differential Side Gear On Special Tool
    GF0006543Courtesy 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 shim or the Belleville spring) on the gauge.
    4. Fig 4: Special Tool On Top Of Differential Clutch Pack
    GF0006544Courtesy of FORD MOTOR CO.
  4. Position the special tool on top of the differential clutch pack.
    5. Fig 5: Special Tool Over Disc & Differential Clutch Pack
    GF0006545Courtesy of FORD MOTOR CO.
  5. Install the special tool over the disc and differential clutch pack.
    6. Fig 6: Nut Of Gauge Over Top & Base Stud
    GF0006546Courtesy 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 7: Checking Clutch Pack Clearance
    GF0006547Courtesy of FORD MOTOR CO.
  7. Use a 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 clutch shim. Select the correct shim size and remove the special tools.
    Part Number Description
    F75Z-4A324-DA 0.030 in
    F75Z-4A324-EA 0.035 in
    F75Z-4A324-FA 0.040 in
    F75Z-4A324-GA 0.045 in
    F75Z-4A324-HA 0.050 in
    F75Z-4A324-JA 0.055 in
    F75Z-4A324-KA 0.060 in
    8. Fig 8: Cutaway View Of Shim, Spring, Clutch Pack & Differential Side Gear
    GF0006548Courtesy of FORD MOTOR CO.
  8. Place the shim and Belleville spring on the differential clutch pack.
    • The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case.
    9. Fig 9: Installing Assembly In Case
    GF0006549Courtesy of FORD MOTOR CO.
  9. Insert the differential clutch packs, the selected shims, Belleville springs and differential side gears into the differential case.
    • Hold the upper differential clutch pack and side gear assembly in place to prevent it from falling out of the differential case.
    10. Fig 10: Installing Special Tools
    GF0006550Courtesy 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 tools in 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 11: Differential Pinion Gears & Differential Pinion Thrust Washers In Window Of Differential Case
    GF0006551Courtesy of FORD MOTOR CO.
    NOTE: Prelubricate both sides of the differential pinion thrust washers with clean rear 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 thrust washers in the window of the differential case so they mesh with the differential side gear teeth.
    12. Fig 12: Special Tool Into Pinion Shaft Bore
    GF0006552Courtesy of FORD MOTOR CO.
    NOTE: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool.
    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 mating shaft holes are lined up exactly with the holes in the differential pinion gears.
    13. Fig 13: Installing Differential Pinion Shaft
    GF0000862Courtesy of FORD MOTOR CO.
  13. Install the differential pinion shaft in the differential case.
    14. Fig 14: Identifying Differential Pinion Shaft Lock Bolt
    GF0000863Courtesy of FORD MOTOR CO.
  14. Install a new differential pinion shaft lock bolt.
    • Tighten to 30 Nm (22 lb-ft).
    15. Fig 15: Checking Rotational Torque (With Specifications)
    GF0006553Courtesy of FORD MOTOR CO.
  15. Check the rotational torque required to rotate one differential side gear.
    • Install the special tool 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.
    16. Fig 16: Identifying 12 Differential Ring Gear Bolts
    GF0003136Courtesy of FORD MOTOR CO.
  16. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the 12 new ring gear bolts.
    • Tighten to 150 Nm (111 lb-ft).
  17. Install the differential carrier. For additional information, refer to Differential Carrier .
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