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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 641 (Rear Drive Axle/Differential - DANA S110 -- F450-F550 Super Duty) >> Disassembly And Assembly >> Differential Case and Ring Gear >> Assembly

Differential Case and Ring Gear: Assembly

WARNING: This page is about a different car, the 2004 Ford F550 Super Duty and 2004 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
  1. If removed, install a new anti-lock speed sensor ring with a dead blow hammer.
    Fig 1: Installing New Anti-Lock Speed Sensor Ring With A Dead Blow Hammer
    G02769066Courtesy of FORD MOTOR CO.
  2. Press the anti-lock speed sensor ring on the case flange.
    Fig 2: Pressing Anti-Lock Speed Sensor Ring On Case Flange
    G02769067Courtesy of FORD MOTOR CO.
  3. Install the inner side gear thrust washer and inner side gear.
    Fig 3: Installing Inner Side Gear Thrust Washer And Inner Side Gear
    G02769068Courtesy of FORD MOTOR CO.
  4. Align the pinion gear cross shaft with the pin hole vertical position.
    Fig 4: Aligning Pinion Gear Cross Shaft With Pin Hole Vertical Position
    G02769069Courtesy of FORD MOTOR CO.
    5. NOTE: Lightly lubricate all of the mating surfaces with clean axle lubricant. This will aid in assembly and provide initial lubrication.
    Fig 5: Installing First Pinion Gear Thrust Washer And Pinion Gear On Pinion Cross Shaft
    G02769070Courtesy of FORD MOTOR CO.
  5. Install the first pinion gear thrust washer and pinion gear on the pinion cross shaft.
  6. Install the second pinion gear and pinion gear thrust washer on the differential cross shaft.
    Fig 6: Installing Second Pinion Gear And Pinion Gear Thrust Washer On Differential Cross Shaft
    G02769071Courtesy of FORD MOTOR CO.
  7. Install the differential cross shaft lock pin.
    Fig 7: Installing Differential Cross Shaft Lock Pin
    G02769072Courtesy of FORD MOTOR CO.
    8. NOTE: There is no thrust washer in this location.
    Fig 8: Installing Outer Side Gear
    G02769073Courtesy of FORD MOTOR CO.
  8. Install the outer side gear.
  9. Align the ring gear and the differential case bolt holes. Install the bolts in the holes finger tight.
    Fig 9: Aligning Ring Gear And Differential Case Bolt Holes
    G02769074Courtesy of FORD MOTOR CO.
  10. Using the special tool and a shop press, press the differential assembly half on the ring gear half.
    Fig 10: Pressing Differential Assembly Half On Ring Gear Half
    G02769075Courtesy of FORD MOTOR CO.
  11. Install the ring gear bolts.
    Fig 11: Installing Ring Gear Bolts
    G02769076Courtesy of FORD MOTOR CO.
  12. Using the special tools, install the ring gear side carrier bearing.
    Fig 12: Installing Ring Gear Side Carrier Bearing
    G02769077Courtesy of FORD MOTOR CO.
  13. Using the special tools, install the differential side carrier bearing.
    Fig 13: Installing Differential Side Carrier Bearing
    G02769078Courtesy of FORD MOTOR CO.
  14. Carefully position the differential assembly into the carrier housing.
    15. CAUTION: The bearing cups must seat on the differential side bearings.
    CAUTION: Align the match marks.
    CAUTION: The bolt threads must be clean.
  15. Install the differential bearing caps.
    1. Position the bearing cap onto the leg.
    2. Apply Threadlock 262 to the bolt threads, and install the bolts.
      • Tighten the bolts enough to eliminate visible space between the bearing cap and leg. Do not tighten the bolts to the appropriate torque at this time.
        Fig 14: Installing Differential Bearing Caps
        G02769079Courtesy of FORD MOTOR CO.
    16. CAUTION: Align the differential assembly within the bearing bores before applying preload or damage to the bearings will result.
  16. Install the differential bearing adjusting rings.
    • Tighten both adjusting rings until there is zero end play, and some backlash between the differential ring gear and pinion. Make sure the adjusting ring tooth aligns so that installation of the adjusting ring cotter pin is possible.
      Fig 15: Adjusting Rings Until There Zero End Play
      G02769080Courtesy of FORD MOTOR CO.
  17. Set the backlash at zero.
      NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.
      Fig 16: Setting Backlash Zero
      G02769081Courtesy of FORD MOTOR CO.
    • Loosen the adjusting ring on the tooth side of the differential ring gear one tooth, and tighten the opposite adjusting ring one tooth. Repeat this process until backlash is at zero.
  18. Set the backlash and the bearing preload to specifications.
    • With a new matched set installed, set the backlash to the specification.
    • With the original matched set installed, set the backlash to the specification recorded prior to disassembly.
      • NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.
      Fig 17: Adjusting Ring Tooth Side Of Differential Ring Gear
      G02769082Courtesy of FORD MOTOR CO.
    • Tighten the adjusting ring on the tooth side of the differential ring gear until backlash is within specifications.
  19. Check the differential ring gear and pinion backlash in four equally spaced positions around the differential ring gear.
    • The acceptable backlash tolerance is +/- 0.0508 mm (0.002 inch) from the backlash specification.
    • If the backlash tolerance varies more than 0.080 mm (0.003 inch) between the four positions, remove the differential and determine the cause.
      Fig 18: Checking Differential Ring Gear And Pinion Backlash
      G02769083Courtesy of FORD MOTOR CO.
  20. Tighten the bolts.
    • Check the differential ring gear and pinion backlash, as described in the previous step, after tightening the bolts.
      Fig 19: Checking Differential Ring Gear And Pinion Backlash
      G02769084Courtesy of FORD MOTOR CO.
  21. Install the adjusting ring cotter pins.
    Fig 20: Installing Adjusting Ring Cotter Pins
    G02769085Courtesy of FORD MOTOR CO.
  22. Install the rear anti-lock brake sensor, if equipped.
    Fig 21: Installing Rear Anti-Lock Brake Sensor
    G02769086Courtesy of FORD MOTOR CO.
  23. Install the carrier. Refer to DIFFERENTIAL CARRIER .
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