Differential Case and Ring Gear - One Piece, Conventional: Assembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Position the differential side gear thrust washers on the differential side gears.
- Use premium long-life grease to lubricate the differential side gear thrust washers and the differential side gear journals.
  
  Fig 1: Positioning Differential Side Gear Thrust Washers On Differential Side Gears
  Courtesy of FORD MOTOR CO.
Position the differential side gears.

Fig 2: Positioning Differential Side Gears
Courtesy of FORD MOTOR CO.
Using premium long-life grease, assemble the differential pinion thrust washers and the differential pinion gears.

Fig 3: Using Premium Long-Life Grease, Assemble Differential Pinion Thrust Washers And Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Engage the differential pinion gears opposite the differential side gears.

Fig 4: Engaging Differential Pinion Gears Opposite Differential Side Gears
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears to align the differential pinion shaft bore.

Fig 5: Aligning Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.

CAUTION: If a new pinion shaft lock bolt is not available, use thread sealant and tighten to specification.

Insert the differential pinion shaft and install a new differential pinion shaft lock bolt.
- Tighten to 30 Nm (23 lb-ft).
  
  Fig 6: Installing A New Differential Pinion Shaft Lock
  Courtesy of FORD MOTOR CO.
Using the special tool, install the differential bearings.

Fig 7: Installing Differential Bearings
Courtesy of FORD MOTOR CO.
Press the new anti-lock speed sensor ring and the ring gear on the differential case.

Fig 8: Pressing New Anti-Lock Speed Sensor Ring And Ring Gear On Differential Case
Courtesy of FORD MOTOR CO.
Using a thread sealant, install the ring gear bolts and tighten.
- Tighten to 150 Nm (110 lb-ft).
  
  Fig 9: Installing Ring Gear Bolts And Tighten
  Courtesy of FORD MOTOR CO.
Install the differential case. Refer to DIFFERENTIAL CASE .