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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 310 (Rear Drive Axle/Differential - Ford 9.75-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.
  1. Prelubricate each steel clutch plate and soak all friction plates with 118 ml (4 ounces) Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.
    Fig 1: Prelubricating Each Steel Clutch Plate
    G02195984Courtesy of FORD MOTOR CO.
    2. NOTE: Do not mix the differential clutch packs or shims from one side with the other.
    NOTE: The Belleville spring is a dished plate.
    Fig 2: Assembling Differential Clutch Packs (Without Shims And Belleville Springs) On Differential Side Gears
    G02195985Courtesy of FORD MOTOR CO.
  2. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.
  3. Clamp the bolt head of the special tool in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.
    Fig 3: Installing Differential Clutch Pack And Differential Side Gear (Without Shim Or Belleville Spring) On Gauge
    G02195986Courtesy of FORD MOTOR CO.
  4. Position the special tool on top of the differential clutch pack.
    Fig 4: Positioning Special Tool On Top Of Differential Clutch Pack
    G02195987Courtesy 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
    G02195988Courtesy of FORD MOTOR CO.
  6. Install the nut over the top and base stud.
    Fig 6: Installing Nut Over Top And Base Stud
    G02195989Courtesy of FORD MOTOR CO.
  7. Use special tool 303-D027 (D81L-4201-A) and select the thickest blade that will enter between the tool and the differential clutch pack. Subtract 0.010 inch from the reading to obtain the thickness of the new clutch shim. A maximum of two shims can be used. Select the correct shim(s) size and remove special tool 205-135 (T80P-4946-A).
    Fig 7: Part Number And Shim Specification Table
    G02195990Courtesy of FORD MOTOR CO.
    Fig 8: Identifying Location For Entering Special Tool For Measuring Clutch Shim Thickness
    G02195991Courtesy of FORD MOTOR CO.
  8. Place the shim and Belleville spring on the differential clutch pack.
    • The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case.
      • Refer to Figure and Figure.
        Fig 9: Placing Shim And Belleville Spring On Differential Clutch Pack
        G02195992Courtesy of FORD MOTOR CO.
  9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case.
    • Hold the upper clutch pack and side gear assembly in place to prevent it from falling out of the differential case.
      Fig 10: Inserting Differential Clutch Packs With Shims And Belleville Springs And Differential Side Gears Into Differential Case
      G02195993Courtesy of FORD MOTOR CO.
    10. NOTE: Apply a small amount of grease to the step plate bore.
    NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.
  10. Assemble the special tool to the differential case.
    1. Position the special tool in the bottom side gear bore.
    2. Position the special tool in the top side gear bore and hold it in place.
    3. Install the special tool and tighten it two turns after it contacts the bottom step plate.
      Fig 11: Positioning Special Tool In Top And Bottom Side Gear Bore
      G02195994Courtesy of FORD MOTOR CO.
    11. NOTE: Prelubricate both sides of the differential pinion thrust washers with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
    NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.
    Fig 12: Positioning Differential Pinion Gears And Differential Pinion Thrust Washers In Window Of Differential Case
    G02195995Courtesy of FORD MOTOR CO.
  11. Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth.
    12. WARNING: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool.
    NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.
    Fig 13: Inserting Special Tool Into Pinion Shaft Bore
    G02195996Courtesy of FORD MOTOR CO.
  12. Insert the special tool into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears.
  13. Loosen the forcing screw, and remove the step plate and nut from the side gear bores. Install a new differential pinion shaft in the differential case.
    • Install the differential pinion shaft lock bolt finger-tight.
      Fig 14: Installing Differential Pinion Shaft Lock Bolt Finger-Tight
      G02195997Courtesy of FORD MOTOR CO.
  14. Install new differential bearings, if removed.
    Fig 15: Installing New Differential Bearings
    G02195998Courtesy of FORD MOTOR CO.
  15. Check the torque required to rotate one differential side gear.
    • Install the special tools with the 1/2-inch drive hole as shown.
    • The initial break-away torque, if original clutch plates are used, must be within specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.
      Fig 16: Installing Special Tool And Checking Torque Required To Rotate Differential Side Gear
      G02195999Courtesy of FORD MOTOR CO.
    16. CAUTION: If equipped, make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
    Fig 17: Installing Differential Ring Gear And New Anti-Lock Speed Sensor Ring On Differential Case
    G02196000Courtesy of FORD MOTOR CO.
    Fig 18: Tightening Differential Ring Gear Bolts
    G02196001Courtesy of FORD MOTOR CO.
  16. Install the differential ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts.
  17. Install the differential case. Refer to DIFFERENTIAL CASE .
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