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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 384 (Rear Drive Axle/Differential 8.8-Inch Ring Gear) >> Disassembly & Assembly >> Differential Case & Ring Gear - Traction-LOK >> Assembly

Differential Case & Ring Gear - Traction-LOK: Assembly

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: 118 ml (4 oz) of the friction modifier must be used in the axle.
    Fig 1: Lubricating Clutch & Friction Plates
    G03434659Courtesy of FORD MOTOR CO.
  1. Lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes with friction modifier.
    2. CAUTION: Do not mix the clutch plates, clutch discs or shim from one side with the other.
    Fig 2: Assembling Differential Clutch Packs On Respective Differential Side Gear
    G03434660Courtesy of FORD MOTOR CO.
  2. Assemble the differential clutch packs (without the shims) on their respective differential side gear.
    3. CAUTION: Use the correct mandrel with the special tool.
    Fig 3: Installing Differential Side Gear & Differential Clutch Pack On Tool
    G03434661Courtesy of FORD MOTOR CO.
  3. Place the base portion of the special tool in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool.
  4. Position the special tool hand-tight on top of the differential clutch pack.
    Fig 4: Positioning Special Tool On Top Of Differential Clutch Pack
    G03434662Courtesy of FORD MOTOR CO.
  5. Install the special tool over the disc and differential clutch pack.
    Fig 5: Installing Special Tool Over Disc & Differential Clutch Pack
    G03434663Courtesy of FORD MOTOR CO.
  6. Install the nut.
    Fig 6: Installing Nut
    G03434664Courtesy of FORD MOTOR CO.
  7. Select and insert the thickest feeler gauge 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 SPECIFICATIONS

    Part Number Description
    EOAZ-4A324-G 0.025 Inch
    EOAZ-4A324-H 0.030 Inch
    EOAZ-4A324-C 0.035 Inch
    EOAZ-4A324-D 0.040 Inch
    EOAZ-4A324-F 0.045 Inch
    Fig 7: Identifying Feeler Gauge Inserting Point
    G03434665Courtesy of FORD MOTOR CO.
  8. Remove the special tool from the differential clutch pack and differential side gear assembly.
  9. Install the shim(s) on the differential clutch pack and differential side gear assembly.
  10. Install the differential side gear assemblies in the differential case.
    Fig 8: Installing Differential Side Gear Assemblies In Differential Case
    G03434666Courtesy of FORD MOTOR CO.
  11. Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case.
    Fig 9: Installing Differential Pinion Gear & Thrust Washer Assemblies
    G03434667Courtesy of FORD MOTOR CO.
  12. Using a soft-faced hammer, install the differential clutch spring.
    Fig 10: Installing Differential Clutch Spring Using Soft-Faced Hammer
    G03434668Courtesy of FORD MOTOR CO.
    13. NOTE: If a new bolt is unavailable, coat the threads with threadlock prior to installation.
    Fig 11: Installing Differential Pinion Shaft & Bolt
    G03434669Courtesy of FORD MOTOR CO.
  13. Install the differential pinion shaft and install a new bolt finger-tight.
  14. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
    • If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.
    Fig 12: Checking One Differential Side Gear Rotational Torque
    G03434670Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the differential bearings.
    Fig 13: Installing Differential Bearing
    G03434671Courtesy of FORD MOTOR CO.
    16. CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring.
    Fig 14: Installing Anti-Lock Speed Sensor Ring & Differential Ring Gear On Differential Case
    G03434672Courtesy of FORD MOTOR CO.
  16. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case.
  17. Install the bolts.
    • Apply stud and bearing mount to the bolt threads.
    Fig 15: Installing Ring Gear Bolts
    G03434673Courtesy of FORD MOTOR CO.
  18. Install the differential assembly. For additional information, refer to DIFFERENTIAL CASE .
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