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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 577 (Rear Drive Axle/Differential-DANA 60 & 70) >> Disassembly And Assembly >> Differential Case and Ring Gear - Model 60, Limited Slip >> Assembly

Differential Case and Ring Gear - Model 60, Limited Slip: Assembly

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    CAUTION: Always install an entirely new stack of clutch plates and discs on both sides if discarding one or more of the clutch plates or clutch discs.
  1. Soak the clutch packs for 20 minutes in friction modifier.
    2. CAUTION: Assemble the rear axle disc and plate kits to the differential side gears in exactly the same order as removed.
  2. Pre-lubricate the differential side gear thrust faces, and assemble the clutch plates and clutch discs onto the differential side gears.
    • Pre-lubricate each part of both stacks with rear axle lubricant or with friction modifier.
  3. Assemble the retainer clips to the clutch plate ears. Both clips must seat completely onto the clutch plate ears.
    Fig 1: Assembling Retainer Clips To Clutch Plate Ears
    G02760731Courtesy of FORD MOTOR CO.
    4. NOTE: Hold the rear axle disc and plate kit to keep it from falling out of the differential case.
    Fig 2: Installing Rear Axle Disc And Plate Kit And Differential Side Gear In Differential Case
    G02760732Courtesy of FORD MOTOR CO.
  4. Install the rear axle disc and plate kit and differential side gear in the differential case.
    • The rear axle disc and plate kit must stay assembled to the differential side gear splines. The retainer clips must seat completely in the differential case pocket.
  5. Install the bottom differential clutch pack and differential side gear in the differential case.
    • The rear axle disc and plate kit must stay assembled to the differential side gear splines. The retainer clips must seat completely in the differential case pocket.
  6. Install the special tool.
    • Apply a small amount of grease to the special tool's centering hole.
    Fig 3: Installing Special Tool
    G02760733Courtesy of FORD MOTOR CO.
  7. Screw the special tool into the Step Plate.
    Fig 4: Screwing Special Tool Into Step Plate
    G02760734Courtesy of FORD MOTOR CO.
  8. Position the differential case onto the holding fixture.
    Fig 5: Positioning Differential Case Onto Holding Fixture
    G02760735Courtesy of FORD MOTOR CO.
  9. Position both differential pinion gears opposite one another in the differential case. Align the differential pinion gear holes with each other. Hold the differential pinion gears in place by hand.
    Fig 6: Positioning Both Differential Pinion Gears Opposite One Another In Differential Case
    G02760736Courtesy of FORD MOTOR CO.
  10. Tighten the special tool enough so that the differential side gears move away from the differential pinion gears and relieve the loaded condition.
    Fig 7: Tightening Special Tool
    G02760737Courtesy of FORD MOTOR CO.
    11. NOTE: Slightly loosen or tighten the special tool to apply the necessary load to allow the differential side gears and differential pinion gears to rotate.
    Fig 8: Inserting Special Tool Into Differential Pinion Shaft Bore
    G02760738Courtesy of FORD MOTOR CO.
  11. While holding the differential pinion gears in place, insert the special tool into the differential pinion shaft bore. Rotate the differential case until the holes of both differential pinion gears align with those in the differential case.
    12. CAUTION: Do not overtighten the special tool. Overtightening can damage the rear axle disc and plate kit.
    Fig 9: Tightening Special Tool
    G02760739Courtesy of FORD MOTOR CO.
  12. Tighten the special tool enough to allow clearance to assemble the differential pinion thrust washers.
    13. NOTE: During assembly, the differential pinion thrust washer and the differential pinion gear holes must align exactly with those in the differential case.
    Fig 10: Assembling Differential Pinion Thrust Washers Into Differential Case
    G02760740Courtesy of FORD MOTOR CO.
  13. Assemble the differential pinion thrust washers into the differential case.
    • Use a very small screwdriver to push the washers into place.
  14. Remove all the tools from the differential case.
  15. Install the differential pinion shaft.
    Fig 11: Installing Differential Pinion Shaft
    G02760741Courtesy of FORD MOTOR CO.
  16. Install the differential pinion shaft lock pin.
    Fig 12: Installing Differential Pinion Shaft Lock Pin
    G02760742Courtesy of FORD MOTOR CO.
  17. If removed, install the differential ring gear.
    • Tighten the Grade 9 bolts to 176 Nm (130 lb-ft).
    Fig 13: Tightening Grade 9 Bolts
    G02760743Courtesy of FORD MOTOR CO.
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