Differential Case and Ring Gear - Conventional: Assembly

WARNING: This page is about a different car, the 2003 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate the differential side gear thrust washers and the differential side gear journals, and assemble the washers to the gears.

Fig 1: Lubricating Differential Side Gear Thrust Washers & Differential Side Gear Journals
Courtesy of FORD MOTOR CO.
Lubricate the differential pinion thrust washers and the differential pinion gears, and assemble the washers to the gears.

Fig 2: Lubricating Differential Pinion Thrust Washers & Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Position the differential side gears and thrust washers into the differential case.

Fig 3: Positioning Differential Side Gears & Thrust Washers Into Differential Case
Courtesy of FORD MOTOR CO.
Engage the differential pinion gears with the differential side gears and rotate the pinion gears to align with the differential pinion shaft bore.

Fig 4: Rotating Pinion Gears To Align With Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Insert the differential pinion shaft.
- Align the hole in the differential pinion shaft with the hole in the differential case.
  
  Fig 5: Aligning Hole In Differential Pinion Shaft With Hole In Differential Case
  Courtesy of FORD MOTOR CO.

NOTE: If a new pinion shaft lock bolt is unavailable, coat the original bolt threads with threadlock and sealer prior to installation.

Fig 6: Installing Differential Pinion Shaft Lock Bolt

Courtesy of FORD MOTOR CO.

Install a new differential pinion shaft lock bolt and tighten finger-tight.
Using the special tool, install the new differential bearings.

Fig 7: Installing Differential Bearings
Courtesy of FORD MOTOR CO.
Press the ring gear on the differential case.
CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.

Fig 8: Pressing Ring Gear On Differential Case
Courtesy of FORD MOTOR CO.

NOTE: Apply stud and bearing mount to the ring gear bolt threads.

Fig 9: Installing Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Install the ring gear bolts.
Install the differential case. For additional information, refer to DIFFERENTIAL CASE .