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

WARNING: This page is about a different car, the 2010 Lincoln Town Car. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Add 118 ml (4 oz) of friction modifier in the axle.

Using the modifier, lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes.

Fig 1: Identifying Friction Plates & Friction Modifier

Courtesy of FORD MOTOR CO.

NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.

Assemble the differential clutch packs on their respective differential side gear.

Fig 2: Identifying Differential Clutch Packs And Differential Side Gears

Courtesy of FORD MOTOR CO.

Place the base portion of the special tool in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool.

Fig 3: Installing Differential Clutch Pack And Differential Side Gear On The Gauge

Courtesy of FORD MOTOR CO.

Position the special tool hand-tight on top of the differential clutch pack.

Fig 4: Positioning Special Tool Hand-Tight On Top Of Differential Clutch Pack

Courtesy of FORD MOTOR CO.

Install the special tool over the disc and differential clutch pack.

Fig 5: Installing Special Tool Over Disc And Differential Clutch Pack

Courtesy of FORD MOTOR CO.

Install the nut.
- Tighten to 6.7 Nm (60 lb-in).

Fig 6: Locating Differential Clutch Pack Nut

Courtesy of FORD MOTOR CO.

Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.

SELECTIVE SHIMS

Part Number	Description
EOAZ-4A324-G	0.025 inch
EOAZ-4A324-H	0.030 inch
EOAZ-4A324-C	0.035 inch
EOAZ-4A324-D	0.040 inch
EOAZ-4A324-F	0.045 inch

Fig 7: Identifying Special Tool In Clutch Pack

Courtesy of FORD MOTOR CO.

Remove the special tool from the differential clutch pack and differential side gear assembly.
Install the shim(s) on the differential clutch pack and differential side gear assembly.
Install the 2 differential side gear assemblies in the differential case.

Fig 8: Identifying Differential Side Gears

Courtesy of FORD MOTOR CO.

Install the 2 differential pinion gear and differential pinion thrust washer assemblies in the differential case.

Fig 9: Identifying Differential Pinion Gears

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Using a soft-faced hammer, install the differential clutch spring.

Fig 10: Installing Differential Clutch Spring

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Install the differential pinion shaft and install a new bolt finger-tight.

Fig 11: Install A New Differential Pinion Shaft Lock Bolt

Courtesy of FORD MOTOR CO.

Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
- If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.

Fig 12: Checking Break-Away Torque

Courtesy of FORD MOTOR CO.

Using the special tool, install the 2 differential bearings.

Fig 13: Installing Differential Bearings On Differential Case

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Position the differential ring gear and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.

Fig 14: Pressing Differential Ring Gear On Differential Case

Courtesy of FORD MOTOR CO.

Install the 10 differential ring gear bolts.
- Apply stud and bearing mount to the bolt threads.
  - Tighten to 114 Nm (84 lb-ft).

Fig 15: Identifying Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Install the differential assembly. For additional information, refer to Differential Case .