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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 309 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear -- F150) >> Disassembly And Assembly >> Differential Case and Ring Gear-Traction-Lok >> Assembly

Differential Case and Ring Gear-Traction-Lok: Assembly

WARNING: This page is about a different car, the 2002 Ford Pickup. 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.
    Fig 1: Soaking Friction Plates With Friction Modifier
    G02192595Courtesy of FORD MOTOR CO.
  1. Prelubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.
    2. CAUTION: Do not mix the differential clutch packs or shims from one side with the other.
    Fig 2: Assembling Differential Clutch Packs On Respective Differential Side Gears
    G02192596Courtesy of FORD MOTOR CO.
  2. Assemble the differential clutch packs (without the shims) on the respective differential side gears.
    3. CAUTION: Make sure the correct mandrel is used with the special tool.
    Fig 3: Installing Differential Clutch Pack And Differential Side Gear With Special Tool
    G02192597Courtesy of FORD MOTOR CO.
  3. 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.
  4. Position the special tool hand-tight on top of the differential clutch pack.
    Fig 4: Positioning Special Tool Hand-Tight On Top Of Differential Clutch Pack
    G02192598Courtesy of FORD MOTOR CO.
  5. Install the special tool over the disc and differential clutch pack.
    Fig 5: Installing Special Tool Over Disc And Differential Clutch Pack
    G02192599Courtesy of FORD MOTOR CO.
  6. Install the nut of the gauge over the top and base stud.
    Fig 6: Installing Nut Of Gauge Over Top And Base Stud
    G02192600Courtesy of FORD MOTOR CO.
    7. NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit F5AZ-4947-BA.
    Fig 7: Selecting Thickest Blade That Will Enter Between Tool And Differential Clutch Pack
    G02192601Courtesy of FORD MOTOR CO.
    Fig 8: Selective Shims Chart
    G02192602Courtesy of FORD MOTOR CO.
  7. Use the 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.

    Selective Shims 

  8. Remove the special tool from the clutch pack and side gear assembly.
  9. Install shims on the clutch pack and side gear assembly.
  10. Install the differential side gear in the differential case.
    Fig 9: Installing Differential Side Gear In Differential Case
    G02192603Courtesy of FORD MOTOR CO.
  11. Install the differential pinion gears with differential pinion thrust washers in the differential case.
    Fig 10: Installing Differential Pinion Gears With Differential Pinion Thrust Washers In Differential Case
    G02192604Courtesy of FORD MOTOR CO.
  12. Using a soft-faced hammer, install the differential clutch spring.
    Fig 11: Installing Differential Clutch Spring
    G02192605Courtesy of FORD MOTOR CO.
  13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.
    Fig 12: Installing Differential Pinion Shaft And Install New Differential Pinion Shaft Lock Bolt
    G02192606Courtesy of FORD MOTOR CO.
  14. Using the special tool, install the differential bearing on the differential case. Repeat for the other side.
    Fig 13: Installing Differential Bearing Of Differential Case
    G02192607Courtesy of FORD MOTOR CO.
    15. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
    Fig 14: Pressing New Anti-Lock Speed Sensor Ring
    G02192608Courtesy of FORD MOTOR CO.
  15. Press the new anti-lock speed sensor ring and the ring gear on the differential case.
    16. NOTE: Apply stud and bearing mount to the ring gear bolts.
    Fig 15: Installing Ring Gear Bolts
    G02192609Courtesy of FORD MOTOR CO.
  16. Install the ring gear bolts.
  17. 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.
    • Refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
      Fig 16: Rotating One Differential Side Gear
      G02192610Courtesy of FORD MOTOR CO.
  18. Install the differential case. Refer to DIFFERENTIAL CASE .
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