Differential Case and Ring Gear - Two-Piece, Traction-Lok: 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.

Prelubricate each clutch disc and soak the clutch friction plates in clean friction modifier.

Fig 1: Prelubricating Clutch Disc And Soak Clutch Friction Plates In Clean Friction Modifier
Courtesy of FORD MOTOR CO.

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

NOTE: The Belleville spring is a dished plate.

Fig 2: Identifying Differential Clutch Packs (Without Shims And Belleville Springs) On Respective Differential Side Gears

Courtesy of FORD MOTOR CO.

Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.
Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the special tool.

Fig 3: Installing Differential Clutch Pack And Differential Side Gear
Courtesy of FORD MOTOR CO.
Install the special tool on top of the differential clutch pack.

Fig 4: Installing Special Tool On Top Of Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Assemble the remaining special tool and tighten the nut.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 5: Assembling Remaining Special Tool
  Courtesy of FORD MOTOR CO.
Use a feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack.
- The reading will be the thickness of the new clutch shim.
- Select the correct shim size.
  
  Fig 6: Measuring Thickness Of New Clutch Shim
  Courtesy of FORD MOTOR CO.
Place the selected shim and Belleville spring on the differential clutch pack.
- The dished or concave side of the Belleville spring must be face up and against the thrust face of the differential case.
  
  Fig 7: Placing Selected Shim And Spring On Differential Clutch Pack
  Courtesy of FORD MOTOR CO.
Install the differential side gear and differential clutch pack into the left case half (ring gear side).

Fig 8: Installing Differential Side Gear And Differential Clutch Pack Into Left Case Half
Courtesy of FORD MOTOR CO.
Position left differential case half on the special tool.

Fig 9: Positioning Left Differential Case Half On Special Tool
Courtesy of FORD MOTOR CO.
Lubricate the differential pinion gears, pinion gear thrust washers and the differential pinion shaft with premium long-life grease.
- Install the differential pinion gears in the differential pinion shaft.
  
  Fig 10: Installing Differential Pinion Gears In Differential Pinion Shaft
  Courtesy of FORD MOTOR CO.
Install the differential pinion shaft and the differential pinion gears.

Fig 11: Installing Differential Pinion Shaft And Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Install the right differential clutch pack and differential side gear into the right case half.

Fig 12: Installing Right Differential Clutch Pack And Differential Side Gear Into Right Case Half
Courtesy of FORD MOTOR CO.
Position the right differential case half with the index marks aligned.

Fig 13: Positioning Right Differential Case Half With Index Marks Aligned
Courtesy of FORD MOTOR CO.
Install the retaining bolts and tighten.
- Tighten to 122 Nm (90 lb-ft).
  
  Fig 14: Installing Retaining Bolts And Tighten
  Courtesy of FORD MOTOR CO.
Using the special tool, check the torque required to rotate one differential side gear.
- The initial break-away torque, if the original clutch plates are used, must be within specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.
  
  Fig 15: Checking Torque Required To Rotate One Differential Side Gear
  Courtesy of FORD MOTOR CO.
Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts.
- Tighten to 150 Nm (110 lb-ft).
  
  Fig 16: Installing Ring Gear And New Anti-Lock Speed Sensor Ring On Differential Case (1 Of 2)
  Courtesy of FORD MOTOR CO.
  
  Fig 17: Installing Ring Gear And New Anti-Lock Speed Sensor Ring On Differential Case (2 Of 2)
  Courtesy of FORD MOTOR CO.
Install the differential case. Refer to DIFFERENTIAL CASE .