Differential Case and Ring Gear - Conventional: Assembly

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Use a vise with brass jaws or wood blocks.

Place the differential case in a vise.
Apply grease to the new differential side gear thrust washers and to the thrust face of the new differential side gears.
Apply grease to the new differential pinion thrust washers and the new differential pinion gears.
Lubricate the differential side gears and differential pinion gears with the specified lubricant.

Fig 1: Lubricating Differential Side Gears And Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Assemble both differential side gears and differential side gear thrust washers. Hold the assembly in place by hand, then assemble the differential pinion gears and differential side gear thrust washers to hold the differential side gears in place.

NOTE: Rotate the differential side gears until the holes of the differential side gear thrust washers and the differential pinion gears line up with the holes of the differential case. If the differential pinion gears cannot be rotated by hand, install one of the axle shafts into the spline of the differential side gear and use a pipe wrench to turn the axle shaft.

Using a drift, line up the holes with those of the differential case.
Assemble the differential pinion shaft and drive on the differential pinion shaft to remove the drift. Align the lock pin hole of the differential pinion shaft with the lock pin hole of the differential case.

Fig 2: Assembling Differential Pinion Shaft And Drive On Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Assemble the differential pinion shaft lock pin. Peen the metal of the differential case over the differential pinion shaft lock pin in two places, 180 degrees apart, to lock in place. Note the location of the slot in the differential pinion shaft lock pin and peen 90 degrees away.

Fig 3: Installing Differential Pinion Shaft Lock Pin
Courtesy of FORD MOTOR CO.

NOTE: The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case.

Fig 4: Aligning Tab In Anti-Lock Speed Sensor Ring With Slot In Differential Case

Courtesy of FORD MOTOR CO.

Align the tab in the anti -lock speed sensor ring with the slot in the differential case. Start the two ring gear bolts through the differential case flange into the ring gear to make sure the differential case and the ring gear bolt hole align.
Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.

Fig 5: Pressing Anti-Lock Speed Sensor Ring On Differential Case
Courtesy of FORD MOTOR CO.
Apply threadlock to the new ring gear bolts.
Install and tighten the Grade 9 ring gear bolts alternately and evenly.

Fig 6: Tightening Grade 9 Ring Gear Bolts
Courtesy of FORD MOTOR CO.

NOTE: For additional information, refer to DIFFERENTIAL CASE AND PINION SET UP .

Install the differential bearings.