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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 367 (Rear Drive Axle/Differential - Ford 9.75 - Inch Ring Gear) >> Disassembly And Assembly >> Differential Case and Ring Gear - Traction-Lok® >> Assembly

Differential Case and Ring Gear - Traction-Lok®: Assembly

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  1. Pre-lubricate each steel clutch plate and soak all friction plates with 118 ml (4 ounces) Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.
    Fig 1: Lubricating Steel Clutch Plate And Soak Friction Plates
    G01948375Courtesy 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
    G01948376Courtesy 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 & Side Gear On Gauge
    G01948377Courtesy 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
    G01948378Courtesy of FORD MOTOR CO.
  5. Install the special tool over the disc and differential clutch pack.
    Fig 5: Installing The Special Tool Over The Disc And Differential Clutch Pack
    G01948379Courtesy of FORD MOTOR CO.
  6. Install the nut over the top and base stud.
    Fig 6: Installing Nut Over The Top And Base Stud
    G01948380Courtesy of FORD MOTOR CO.
    7. NOTE: These shims are available as part of Clutch Pack Replacement Kit F75Z- 4947-AA.
    Fig 7: Identifying Clutch Pack Measuring Location
    G01948381Courtesy of FORD MOTOR CO.
    Fig 8: Shim Specification Table
    G01948382Courtesy 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. Subtract 0.010 inch from the feeler gauge reading. This will be the thickness of the new clutch shim. Select the correct shim size, and remove the Traction-Lok Clutch Gauge.
  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.
    Fig 9: Cross-Sectional View Of Belleville Spring Installation
    G01948383Courtesy 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: Installing Differential Clutch Packs
    G01948384Courtesy 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.
    Fig 11: Installing Special Tool In Differential Case
    G01948385Courtesy of FORD MOTOR CO.
  10. Assemble the special tool to the differential case.
    1. Position the step plate in the bottom side gear bore.
    2. Position the nut in the top side gear bore and hold it in place.
    3. Install the hex-head screw and tighten it two turns after it contacts the bottom step plate.
    11. NOTE: Pre-lubricate 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
    G01948386Courtesy 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
    G01948387Courtesy 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
    G01948388Courtesy of FORD MOTOR CO.
  14. Install new differential bearings, if removed.
    Fig 15: Installing New Differential Bearings
    G01948389Courtesy of FORD MOTOR CO.
  15. Check the torque required to rotate one differential side gear.
    • Mount the differential case and the Traction-Lok Torque Tool Set in a vise.
    • 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 can vary.
    Fig 16: Checking Torque
    G01948390Courtesy of FORD MOTOR CO.
    16. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
    Fig 17: Installing Ring Gear
    G01948391Courtesy of FORD MOTOR CO.
    Fig 18: Tightening Ring Gear Bolts
    G01948392Courtesy of FORD MOTOR CO.
  16. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the bolts.
  17. Install the differential case. For additional information, refer to DIFFERENTIAL CASE .
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