Differential Case and Ring Gear - Two-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 Clutch Friction Plates

Courtesy of FORD MOTOR CO.

Prelubricate each clutch disc and soak the clutch friction plates in clean friction modifier.

Fig 2: Exploded View Of Clutch Pack And Side Gear

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NOTE: Do not mix the differential clutch packs or shims from one side with the other.

Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.

Fig 3: Differential Clutch Pack & Differential Side Gear On Special Tool

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Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the special tool.

Fig 4: Special Tool On Top Of Differential Clutch Pack

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Install the special tool on top of the differential clutch pack.

Fig 5: Nut Of Gauge Over Top & Base Stud

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Assemble the remaining special tool and tighten the nut.
- Tighten to 6.7 Nm (60 lb-in).

Fig 6: Checking Clearance

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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.

Fig 7: Selected Shim & Belleville Spring On Differential Clutch Pack

Courtesy of FORD MOTOR CO.

NOTE: The dished or concave side of the Belleville spring must be face up and against the thrust face of the differential case.

Place the selected shim and Belleville spring on the differential clutch pack.

Fig 8: Differential Side Gear & Differential Clutch Pack In Left Case Half

Courtesy of FORD MOTOR CO.

Install the differential side gear and differential clutch pack into the left case half.

Fig 9: Left Differential Case Half On Special Tool

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Position left differential case half on the special tool.

Fig 10: Lubricating Differential Pinion Gears, Pinion Gear Thrust Washers & Differential Pinion Shaft

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NOTE: Lubricate the differential pinion gears, pinion gear thrust washers and the differential pinion shaft with long-life grease.

Install the differential pinion gears and thrust washers on the differential pinion shaft.

Fig 11: Installing Differential Pinion Shaft & Differential Pinion Gears

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Install the differential pinion shaft and the differential pinion gears.

Fig 12: Differential Side Gear & Differential Clutch Pack In Right Case Half

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Install the right differential clutch pack and differential side gear into the right case half.

Fig 13: Aligning Differential Case Halves

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Position the right differential case half with the index marks aligned.

Fig 14: Differential Case Bolts

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Install the 6 retaining bolts.
- Tighten to 122 Nm (90 lb-ft).

Fig 15: Checking Rotating Torque (With Specifications)

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Using the special tool, check the torque required to rotate one differential side gear.
- The initial break-away torque, if the 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.

Fig 16: Pressing Anti-Lock Speed Sensor Ring & Ring Gear On Differential Case

Courtesy of FORD MOTOR CO.

Install the 12 new ring gear bolts and, if removed, a new anti-lock speed sensor ring on the differential case.
- Tighten to 150 Nm (111 lb-ft).

Fig 17: Identifying 12 Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Install the differential carrier. For additional information, refer to Differential Carrier .