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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 777 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear) >> Disassembly And Assembly >> Differential Case and Ring Gear - Traction-Lok® >> Assembly

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

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    CAUTION: 118 ml (4 oz) of the specified friction modifier must be used in the axle.
    Fig 1: Prelubricating Each Steel Clutch Plate
    G03878750Courtesy of FORD MOTOR CO.
  1. Prelubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.
    2. CAUTION: Do not mix the differential clutch packs or shims from one side with the other.
    Fig 2: Identifying Differential Clutch Packs And Differential Side Gears
    G03878751Courtesy of FORD MOTOR CO.
  2. Assemble the differential clutch packs (without the shims) on the respective differential side gears.
    3. CAUTION: Select the correct mandrel to use with the Traction-Lok Differential Gauge.
    Fig 3: Installing Differential Clutch Pack And Differential Side Gear
    G03884248Courtesy of FORD MOTOR CO.
  3. Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge.
  4. Position the special tool hand-tight on top of the differential clutch pack.
    Fig 4: Positioning Special Tool Hand-Tight On Top Of Differential Clutch Pack
    G03884249Courtesy of FORD MOTOR CO.
  5. Install the special tool over the disc and differential clutch pack.
    Fig 5: Installing Special Tool Over Disc And Differential Clutch Pack
    G03884250Courtesy of FORD MOTOR CO.
  6. Install the nut of the gauge over the top and base stud.
    Fig 6: Installing Nut Of Gauge Over Top And Base Stud
    G03884251Courtesy of FORD MOTOR CO.
  7. Select the thickest blade of a suitable feeler gauge that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim.
    SELECTIVE SHIMS

    Part Number Description
    E0AZ-4A324-G 0.025 Inch
    E0AZ-4A324-H 0.030 Inch
    E0AZ-4A324-C 0.035 Inch
    E0AZ-4A324-D 0.040 Inch
    E0AZ-4A324-F 0.045 Inch
    Fig 7: Inserting Feeler Gauge Between Tool And Differential Clutch Pack
    G03878756Courtesy of FORD MOTOR CO.
  8. Remove the special tool from the clutch pack and side gear assembly.
  9. Install the selected shims on the clutch pack and side gear assembly.
  10. Install the differential side gear in the differential case.
    Fig 8: Installing Differential Side Gear Differential Case
    G03884253Courtesy of FORD MOTOR CO.
  11. Install the differential pinion gears with differential pinion thrust washers in the differential case.
    Fig 9: Installing Differential Pinion Gears With Differential Pinion Thrust Washers
    G03878758Courtesy of FORD MOTOR CO.
  12. Install the differential clutch spring, using a soft-faced hammer.
    Fig 10: Installing Differential Clutch Spring
    G03878759Courtesy of FORD MOTOR CO.
  13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.
    Fig 11: Installing New Differential Pinion Shaft Lock Bolt Finger-Tight
    G03878760Courtesy of FORD MOTOR CO.
  14. Using the special tool, install the differential bearing on the differential case. Repeat for the other side.
    Fig 12: Installing Differential Bearing On Differential Case
    G03884257Courtesy of FORD MOTOR CO.
  15. Install the anti-lock speed sensor.
    • Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly.
  16. Press the new anti-lock speed sensor ring and the ring gear on the differential case.
  17. Install the ring gear bolts.
    • Apply sealer to the ring gear bolts.
      Fig 13: Installing Ring Gear Bolts
      G03884258Courtesy of FORD MOTOR CO.
  18. Check the torque required to rotate one differential side gear.
    • Mount the differential case and special tool in a vise.
    • The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.
    • For additional information, refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
      Fig 14: Turning With New Clutch Plates
      G03884259Courtesy of FORD MOTOR CO.
  19. Install the differential case. For additional information, refer to DIFFERENTIAL CASE .
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