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

CAUTION: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the axle.

NOTE: Differential Clutch Pack Rebuild Kit F5ZZ-4947-BA is available for rebuild of the 7.5-inch ring gear, Traction-Lok®.

Prelubricate each steel clutch plate and soak all friction plates with additive friction modifier for at least 15 minutes.

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

Fig 1: Assembling Differential Clutch Packs

Courtesy of FORD MOTOR CO.

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

CAUTION: Make sure the correct mandrel is used with the special tool.

Fig 2: Installing Differential Clutch Pack & Differential Side Gear (Without Shim) On Gauge

Courtesy of FORD MOTOR CO.

Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge.
Position the special tool hand-tight on top of the differential clutch pack.

Fig 3: Positioning Special Tool On Top Of Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the special tool over the disc and clutch pack.

Fig 4: Installing Special Tool Over Disc & Clutch Pack
Courtesy of FORD MOTOR CO.
Install the nut of the special tool over the top and base stud.

Fig 5: Installing Nut Of Special Tool Over Top & Base Stud
Courtesy of FORD MOTOR CO.
Use a suitable 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 6: Selective Shims Specification Table
Courtesy of FORD MOTOR CO.

Fig 7: Using Feeler Gauge To Select Thickness Of New Shim
Courtesy of FORD MOTOR CO.
Remove the special tool from the clutch pack and side gear assembly.
Install shims on the clutch pack and side gear assembly.
Install the differential side gears in the differential case.

Fig 8: Installing Differential Side Gears In Differential Case
Courtesy of FORD MOTOR CO.
Install the differential pinion gears with differential pinion thrust washers in the differential case.

Fig 9: Installing Differential Pinion Gears With Differential Pinion Thrust Washers In Differential Case
Courtesy of FORD MOTOR CO.
Using a soft-faced hammer, install the differential clutch spring.

Fig 10: Installing Differential Clutch Spring
Courtesy of FORD MOTOR CO.

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

Fig 11: Installing Differential Pinion Shaft & Differential Pinion Shaft Lock Bolt

Courtesy of FORD MOTOR CO.

Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.
Check the torque required to rotate one differential side gear.
- Mount the differential case and special tool in a vise.
- The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.
  
  Fig 12: Checking Torque Required To Rotate One Differential Side Gear
  Courtesy of FORD MOTOR CO.
Using the special tool, install the differential bearing on the differential case. Repeat for the other side.

Fig 13: Installing Differential Bearing On Differential Case
Courtesy of FORD MOTOR CO.

CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.

Fig 14: Pressing Anti-Lock Speed Sensor Ring & Ring Gear On Differential Case

Courtesy of FORD MOTOR CO.

Press the new anti-lock speed sensor ring and the ring gear on the differential case.

NOTE: Apply stud and bearing mound to the ring gear bolts.

Fig 15: 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 .