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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 640 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> Disassembly And Assembly >> Differential Case and Ring Gear - Traction-Lok® >> Assembly

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

WARNING: This page is about a different car, the 2004 Ford Pickup and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Soak the clutch packs for 20 minutes in friction modifier before assembly.
  2. Place the side gear ring on the pinion flange. Coat the rear axle disc and plate kit with lubricant and place it on the side gear ring.
    • Use rear axle lubricant or friction modifier.
      Fig 1: Placing Side Gear Ring On Pinion Flange
      G02768997Courtesy of FORD MOTOR CO.
    3. CAUTION: After assembly, make sure that the side gear splines engage the clutch pack splines and the differential side gear is fully seated.
    Fig 2: Installing Side Gear Ring
    G02768998Courtesy of FORD MOTOR CO.
  3. Install the side gear ring, the rear axle disc and plate kit and the side gear in the flange half of the differential case.
    4. NOTE: For vehicles operating at close to their GVW rating, typically emergency vehicles and vehicles equipped with a fifth wheel, there may be circumstances of continuing chatter/bumping in turns despite the installation of new parts and lubricant. In cases such as this, it is permissible to reassemble the rear axle disc and plate kit with the clutch disc adjacent to the differential side gear ring, resulting in 2 clutch plates together. This results in 3 friction surfaces instead of the normal 5, lowering the torque to rotate the wheel by 40 percent.
    Fig 3: Installing Side Gear Ring
    G02768999Courtesy of FORD MOTOR CO.
  4. Align the clutch pressure plate lugs, and install the side gear ring, the clutch pack and differential side gear in the button half of the differential case.
    5. CAUTION: Align the match marks made during disassembly.
    Fig 4: Placing Differential Pinion Shaft And Differential Pinion
    G02769000Courtesy of FORD MOTOR CO.
  5. Place the differential pinion shaft and differential pinion gears in the button half of the differential case.
    6. CAUTION: Align the match marks made during disassembly.
    Fig 5: Installing Differential Pinion Shaft And Differential Pinion Gears In Flange
    G02769001Courtesy of FORD MOTOR CO.
  6. Install the other differential pinion shaft and differential pinion gears in the flange half of the differential case.
    7. CAUTION: Align the match marks made during disassembly.
  7. Assemble the differential case.
    1. Place the button half of the differential case onto the flange half of the differential case assembly.
      2. CAUTION: The bolts must be clean and dry.
    2. Install the bolts. Turn each one in a few threads.
    3. Tighten the bolts evenly and alternately.
      • Tighten to 129 Nm (95 lb-ft).
        Fig 6: Installing Bolts
        G02769002Courtesy of FORD MOTOR CO.
  8. If assembled correctly, each differential pinion shaft will fit tight on its ramp. Clearance between the differential pinion shaft and the ramp must not be more than 0.254 mm (0.010 inch) and it must be equal at all four ends of the differential pinion shafts.
  9. Install the differential case. Refer to DIFFERENTIAL CASE .
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