Differential Case and Ring Gear - Conventional: Assembly

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Use rear axle lubricant to lubricate the differential side gear thrust washer and the differential side gear journals.
- Position the differential side gear thrust washer on the differential side gear.
  
  Fig 1: Positioning Differential Side Gear Thrust Washer On Differential Side Gear
  Courtesy of FORD MOTOR CO.
Position the differential side gear.

Fig 2: Positioning Differential Side Gear And Thrust Washer Assemblies In Differential Case
Courtesy of FORD MOTOR CO.
Use rear axle lubricant to lubricate the differential pinion gear thrust washer and the differential pinion gear.

Fig 3: Lubricating Differential Pinion Gear Thrust Washer And Differential Pinion Gear
Courtesy of FORD MOTOR CO.
Engage the differential pinion gears and the differential side gears.

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

Fig 5: Aligning Pinion Gears With Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Insert the differential pinion shaft.
- Align the hole in the differential pinion shaft with the hole in the differential case.
  
  Fig 6: Identifying Differential Pinion Shaft
  Courtesy of FORD MOTOR CO.
Install a new differential pinion shaft lock bolt and tighten finger-tight.

Fig 7: Identifying Differential Pinion Shaft Lock Bolt
Courtesy of FORD MOTOR CO.
Using the special tool, install the new differential bearings on the differential case.

Fig 8: Installing New Differential Bearings On Differential Case
Courtesy of FORD MOTOR CO.
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 9: Installing Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
Install the differential case. For additional information, refer to DIFFERENTIAL CASE .