Differential Case: 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 gears, and assemble them.
- Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
  
  Fig 1: Assembling Differential Side Gear Thrust Washers & Differential Side Gears
  Courtesy of FORD MOTOR CO.
Position the differential side gear and thrust washer assemblies in the differential case.

Fig 2: Positioning Differential Side Gear & Thrust Washer Assemblies In Differential Case
Courtesy of FORD MOTOR CO.
Lubricate the differential pinion thrust washers and the differential pinion gears, and assemble them.
- Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
  
  Fig 3: Assembling Differential Pinion Thrust Washers & Differential Pinion Gears
  Courtesy of FORD MOTOR CO.
Engage the differential pinion gears between the differential side gears.

Fig 4: Engaging Differential Pinion Gears Between Differential Side Gears
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears and align them with the differential pinion shaft bore.

Fig 5: Rotating Differential Pinion Gears & Aligning Them With Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Insert the differential pinion shaft.

Fig 6: Inserting Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Install the differential pinion shaft roll pin.

Fig 7: Installing Differential Pinion Shaft Roll Pin
Courtesy of FORD MOTOR CO.
Install the differential bearing shims, the differential bearings, and the differential ring gear. For additional information, refer to AXLE .