Differential Case and Ring Gear - Traction-Lok® Special Tool(s): 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.

CAUTION: 118 ml (4 oz) of the specified friction modifier must be used in the axle.

Fig 1: Prelubricating Steel Clutch Plate

Courtesy of FORD MOTOR CO.

Prelubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.

CAUTION: Do not mix the differential clutch packs or shims from one side with the other.

Fig 2: Assembling Differential Clutch Packs On Respective Differential Side Gears

Courtesy of FORD MOTOR CO.

Assemble the differential clutch packs (without the shims) on the respective differential side gears.

CAUTION: Select the correct mandrel to use with the Traction-Lok Differential Gauge.

Fig 3: Installing Differential Clutch Pack And Differential Side Gear On Gauge

Courtesy of FORD MOTOR CO.

Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge.
Position the special tool hand-tight on top of the differential clutch pack.

Fig 4: Positioning Special Tool On Top Of Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the special tool over the disc and differential clutch pack.

Fig 5: Installing Special Tool Over Disc And Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the nut of the gauge over the top and base stud.

Fig 6: Installing Nut Of Gauge Over Top And Base Stud
Courtesy of FORD MOTOR CO.

Select the thickest blade of a suitable feeler gauge that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.

SELECTIVE SHIMS

Part Number	Description
E0AZ-4A324-G	0.025 Inch
E0AZ-4A324-H	0.030 Inch
E0AZ-4A324-C	0.035 Inch
E0AZ-4A324-D	0.040 Inch
E0AZ-4A324-F	0.045 Inch

Fig 7: Measuring Thickness Of New Clutch Shim

Courtesy of FORD MOTOR CO.

Remove the special tool from the clutch pack and side gear assembly.
Install the selected shims on the clutch pack and side gear assembly.
Install the differential side gear in the differential case.

Fig 8: Installing Differential Side Gear In Differential Case
Courtesy of FORD MOTOR CO.
Install the differential pinion gears with differential pinion thrust washers in the differential case.

Fig 9: Installing Differential Pinion Gears With Differential Pinion Thrust Washers In Differential Case
Courtesy of FORD MOTOR CO.
Install the differential clutch spring, using a soft-faced hammer.

Fig 10: Installing Differential Clutch Spring
Courtesy of FORD MOTOR CO.
Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.

Fig 11: Installing Differential Pinion Shaft And New Shaft Lock Bolt
Courtesy of FORD MOTOR CO.
Using the special tool, install the differential bearing on the differential case. Repeat for the other side.

Fig 12: Installing Differential Bearing On Differential Case
Courtesy of FORD MOTOR CO.
Install the anti-lock speed sensor.
- Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly.
Press the new anti-lock speed sensor ring and the ring gear on the differential case.
Install the ring gear bolts.
- Apply sealer to the ring gear bolts.
Fig 13: Installing Ring Gear Bolts
Courtesy of FORD MOTOR CO.
Check the torque required to rotate one differential side gear.
- Mount the differential case and special tool in a vise.
- The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.
- For additional information, refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
Fig 14: Checking Torque Required To Rotate One Differential Side Gear
Courtesy of FORD MOTOR CO.
Install the differential case. For additional information, refer to DIFFERENTIAL CASE .