Differential Case and Ring Gear - Conventional: Assembly
WARNING: This page is about a different car, the 2005 Ford Pickup and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Place the differential case in a vise.
- Lubricate the new differential side gear thrust washers, the thrust face of the new differential side gears, the new differential pinion thrust washers and the new differential pinion gears with grease.
- Lubricate and assemble both differential side gears and differential side gear thrust washers. Hold them in place. Then, lubricate and assemble the differential pinion gears and the differential pinion gear thrust washers to hold the differential side gears in place.
- Using a drift, line up the holes with those of the differential case.
- Assemble the differential pinion shaft and drive on the differential pinion shaft to remove the drift. Align the lock pin hole in the differential pinion shaft with the lock pin hole in the differential case.
- Assemble the differential pinion shaft lock pin. Peen the metal of the differential case over the differential pinion shaft lock pin in two places, 180 degrees apart, to lock it in place. Note the location of the slot in the differential pinion shaft lock pin and peen it 90 degrees apart.
- Install the differential case. For additional information, refer to DIFFERENTIAL CASE .
NOTE:
Use a vise with brass jaws or wood blocks.
NOTE:
The best way to assemble the differential side gears and the differential pinion gears is to lubricate all parts with the specified rear axle lubricant.
NOTE:
Rotate the differential side gears until the holes of the differential pinion gear thrust washers and the differential pinion gears line up with the holes of the differential case. If the differential pinion gears will not rotate by hand, install one of the axle shafts into the spline of the differential side gear and use a pipe wrench to turn the axle shaft.