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 with rear axle lubricant.
Position the differential side gear thrust washers on the differential side gears.

Fig 1: Positioning Differential Side Gear Thrust Washers On Differential Side Gears
Courtesy of FORD MOTOR CO.
Position the differential side gear and thrust washer assemblies in the differential case (4204).

Fig 2: Positioning Differential Side Gear & Thrust Washer Assemblies In Differential Case
Courtesy of FORD MOTOR CO.
Lubricate the differential pinion thrust washers and differential pinion gears with rear axle lubricant.
Assemble the differential pinion thrust washers and the differential pinion gears.

Fig 3: Assembling Differential Pinion Thrust Washers & Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Engage the differential pinion gears opposite the differential side gears. Rotate the differential pinion gears to align with the differential pinion shaft bore.

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

NOTE: If a new bolt is unavailable, coat the threads with threadlock prior to installation.

Fig 6: Installing Bolt

Courtesy of FORD MOTOR CO.

Install a new bolt finger-tight.
Using the special tool, install the new differential bearings.

Fig 7: Installing Differential Bearings
Courtesy of FORD MOTOR CO.

CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring.

Fig 8: Pressing Anti-Lock Speed Sensor Ring & Differential Ring Gear On Differential Case

Courtesy of FORD MOTOR CO.

Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case.
Install the bolts.
- Apply stud and bearing mount to the bolt threads.
  
  Fig 9: Installing Bolts
  Courtesy of FORD MOTOR CO.
Install the differential assembly. For additional information, refer to DIFFERENTIAL CASE .