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Differential Case: Assembly

WARNING: This page is about a different car, the 2002 Ford Pickup, 2001 Ford Pickup, and 2000 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the differential side gear thrust washers and the differential side gear journals with Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A.
  2. Position the differential side gear thrust washers on the differential side gears.
    Fig 1: Positioning Differential Side Gear Thrust Washers On Differential Side Gears
    G02187234Courtesy of FORD MOTOR CO.
  3. Position the differential side gears.
    Fig 2: Positioning Differential Side Gears
    G02187235Courtesy of FORD MOTOR CO.
  4. Lubricate the differential pinion thrust washers and the differential pinion gears and assemble them.
    • Use Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A.
      Fig 3: Assembling Differential Pinion Thrust Washers & Differential Pinion Gears
      G02187236Courtesy of FORD MOTOR CO.
  5. Engage the differential pinion gears opposite the differential side gears.
    Fig 4: Engaging Differential Pinion Gears Opposite The Differential Side Gears
    G02187237Courtesy of FORD MOTOR CO.
  6. Rotate the differential pinion gears to align with the differential pinion shaft bore.
    Fig 5: Rotating Differential Pinion Gears To Align With Differential Pinion Shaft Bore
    G02187238Courtesy of FORD MOTOR CO.
  7. Insert the differential pinion shaft.
    Fig 6: Inserting Differential Pinion Shaft
    G02187239Courtesy of FORD MOTOR CO.
    8. NOTE: If a new pinion shaft bolt is unavailable, coat the threads with Threadlock® and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation.
    Fig 7: Installing New Differential Pinion Shaft Bolt
    G02187240Courtesy of FORD MOTOR CO.
  8. Install a new differential pinion shaft bolt.
    9. CAUTION: Do not press on the bearing.
  9. Install the ring gear.
    1. Position three bolts to align the holes in the ring gear and the differential case.
    2. Using a suitable press, install the ring gear.
      Fig 8: Installing Ring Gear
      G02187241Courtesy of FORD MOTOR CO.
  10. Install the remaining bolts.
    Fig 9: Tightening Ring Gear Bolts
    G02187242Courtesy of FORD MOTOR CO.
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