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.

Position the differential side gear thrust washers on the differential side gears.
- Lubricate the differential side gear thrust washers and the differential side gear journals with rear axle lubricant.
  
  Fig 1: Identifying Differential Thrust Washers & Differential Side Gears
  Courtesy of FORD MOTOR CO.
Position the differential side gears.

Fig 2: Positioning Differential Side Gears
Courtesy of FORD MOTOR CO.
Assemble the differential pinion thrust washers and the differential pinion gears.
- Lubricate the pinion gears and the pinion thrust washers with rear axle lubricant.
  
  Fig 3: Assembling 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.
Using the special tool, install the differential bearings.

Fig 5: Installing Differential Bearings
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears to align the differential pinion shaft bore.

Fig 6: Aligning Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.

Fig 7: Installing Differential Pinion Shaft Lock Bolt Finger-Tight
Courtesy of FORD MOTOR CO.

CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.

Fig 8: Positioning Differential Ring Gear

Courtesy of FORD MOTOR CO.

Press the new anti-lock speed sensor ring and the ring gear on the differential case.
Install the bolts and tighten.
- 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 .