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

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.

Fig 1: Lubricating Each Steel Clutch Plate And Soaking All Friction Plates With Friction Modifier
Courtesy of FORD MOTOR CO.

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

NOTE: The Belleville spring is a dished plate.

Fig 2: Assembling Differential Clutch Packs On Differential Side Gears

Courtesy of FORD MOTOR CO.

Assemble the differential clutch packs (without the selective shims and Belleville springs) on their respective differential side gears.
Clamp the bolt head of the special tool in a vise. Install the differential clutch pack and the differential side gear (without the selective shim or the Belleville spring) on the special tool.

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

Fig 4: Positioning Special Tool (205-135) On Top Of Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the special tool over the disc and differential clutch pack.

Fig 5: Installing Special Tool (205-135) Over Disc And Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the nut over the top and base stud.
- Tighten to 7 Nm (62 lb-in).
Fig 6: Installing Nut Over Top And Base Stud
Courtesy of FORD MOTOR CO.

NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit F5AZ-4947-BA.

Fig 7: Inserting Feeler Gauge Between Tool And Differential Clutch Pack

Courtesy of FORD MOTOR CO.

Use the 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 selective shim.

Selective Shims

SELECTIVE SHIMS SPECIFICATIONS

Part Number	Description
E0AZ-4A324-H	0.030 in
E0AZ-4A324-C	0.035 in
E0AZ-4A324-D	0.040 in
E0AZ-4A324-F	0.045 in

Place the selective shim and Belleville spring on the differential clutch pack.
- The dished or concave side of the Belleville spring must face up against the thrust face of the differential case.
Fig 8: Installing Selective Shim And Belleville Spring On Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the differential side gears with the differential clutch packs, selective shims and Belleville spring into the differential case.
- Hold the differential side gear assembly in place to prevent it from falling out of the differential case.
Fig 9: Installing Differential Side Gears With Differential Clutch Packs, Selective Shims And Belleville Spring Into Differential Case
Courtesy of FORD MOTOR CO.

NOTE: Apply a small amount of grease to the step plate bore.

NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.

Fig 10: Assembling Special Tool To Differential Case

Courtesy of FORD MOTOR CO.

Assemble the special tool to the differential case.
1. Position the special tool in the bottom differential side gear.
2. Position the special tool in the top differential side gear and hold it in place.
3. Install the special tool and tighten it 2 turns after it contacts the bottom step plate.

NOTE: Lubricate both sides of the differential pinion gear thrust washers with axle lubricant.

NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.

Fig 11: Positioning Differential Pinion Gears And Differential Pinion Gear Thrust Washers In Window Of Differential Case

Courtesy of FORD MOTOR CO.

Position the differential pinion gears and differential pinion gear thrust washers in the window of the differential case so they mesh with the differential side gear teeth.

WARNING: Keep fingers and hands away from differential pinion gears when rotating the differential case with the differential rotating tool.

NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.

Fig 12: Inserting Special Tool Into Pinion Shaft Bore And Turning Differential Case

Courtesy of FORD MOTOR CO.

Insert the special tool into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion shaft mating holes are lined up exactly with the holes in the differential pinion gears.
Remove the special tools.

NOTE: If a new differential pinion shaft lock bolt is unavailable, coat the threads of the original differential pinion shaft lock bolt with threadlock prior to installation.

Fig 13: Installing Differential Pinion Shaft, Then A New Differential Pinion Shaft Lock Bolt Finger-Tight

Courtesy of FORD MOTOR CO.

Install the differential pinion shaft, then a new differential pinion shaft lock bolt finger-tight.
Install new differential bearings.

Fig 14: Installing New Differential Bearings
Courtesy of FORD MOTOR CO.
Check the torque required to rotate one differential side gear.
- Install the special tools with the 1/2-inch drive hole as shown.
- The initial break-away torque, if 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 differential ring gear and, if removed, a new anti-lock ring.

Fig 16: Installing Differential Ring Gear And, If Removed, A New Anti-Lock Ring
Courtesy of FORD MOTOR CO.

NOTE: Apply stud and bearing mount to the differential ring gear bolts.

Fig 17: Installing 12 Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Install the 12 differential ring gear bolts.
- Tighten to 150 Nm (111 lb-ft).
Install the differential carrier assembly in the axle housing.

Fig 18: Installing Differential Carrier Assembly In Axle Housing
Courtesy of FORD MOTOR CO.
Install a differential bearing shim on the LH side.

Fig 19: Installing Differential Bearing Shim On Left Side
Courtesy of FORD MOTOR CO.

CAUTION: Index mark the position of the differential bearing caps as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.

NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.

Fig 20: Installing LH Differential Bearing Cap And Loosely Installing Differential Bearing Cap Bolts

Courtesy of FORD MOTOR CO.

Install the LH differential bearing cap and loosely install the differential bearing cap bolts.
Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.

Fig 21: Installing Progressively Larger Differential Bearing Shims On RH Side
Courtesy of FORD MOTOR CO.
Install the RH side differential bearing cap and tighten the LH side and RH side differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).
Fig 22: Installing RH Side Differential Bearing Cap And Tightening LH Side And RH Side Differential Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
Rotate the differential assembly to make sure it rotates freely.

Fig 23: Rotating Differential Assembly
Courtesy of FORD MOTOR CO.

NOTE: If ring gear backlash is within specification, go to Step 30.

NOTE: Specification shown is the maximum ring gear backlash allowable.

Fig 24: Measuring Ring Gear Backlash Using Special Tools

Courtesy of FORD MOTOR CO.

Using the special tools, measure ring gear backlash.

NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.

Fig 25: Installing Thicker Differential Bearing Shim And Thinner Differential Bearing Shim

Courtesy of FORD MOTOR CO.

To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.

If ring gear backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.

BACKLASH ADJUSTMENT DIFFERENTIAL BEARING SHIM THICKNESS SPECIFICATIONS

Backlash Change Required		Thickness Change Required
mm	in	mm	in
0.025	0.001	0.050	0.002
0.050	0.002	0.050	0.002
0.076	0.003	0.101	0.004
0.101	0.004	0.152	0.006
0.127	0.005	0.152	0.006
0.152	0.006	0.203	0.008
0.177	0.007	0.254	0.010
0.203	0.008	0.254	0.010
0.228	0.009	0.304	0.012
0.254	0.010	0.355	0.014
0.279	0.011	0.355	0.014
0.304	0.012	0.406	0.016
0.330	0.013	0.457	0.018
0.335	0.014	0.457	0.018
0.381	0.015	0.508	0.020

NOTE: The bearing caps must be removed before differential bearing shims can be installed.

Fig 26: Installing Thicker Differential Bearing Shim And Thinner Differential Bearing Shim Of Same Thickness

Courtesy of FORD MOTOR CO.

To decrease ring gear backlash, install a thicker differential bearing shim (A) and a thinner differential bearing shim of the same thickness (B) as shown.
Rotate the differential assembly several times to make sure the differential bearings are seated.

Fig 27: Rotating Differential Assembly
Courtesy of FORD MOTOR CO.
Using the special tools, recheck the ring gear backlash.

Fig 28: Rechecking Ring Gear Backlash Using Special Tools
Courtesy of FORD MOTOR CO.
Remove the differential bearing cap bolts (A) and differential bearing caps (B).

Fig 29: Removing Differential Bearing Cap Bolts And Differential Bearing Caps
Courtesy of FORD MOTOR CO.

NOTE: To establish differential bearing preload, increase both left and right differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.

Fig 30: Installing Differential Bearing Shims Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, install the differential bearing shims.
Install the differential bearing caps and differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).
Fig 31: Identifying Differential Bearing Caps And Differential Bearing Cap Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the axle and the differential housing cover.
Apply a new, continuous bead of sealant to the differential housing cover.

Fig 32: Applying New Continuous Bead Of Sealant To Differential Housing Cover
Courtesy of FORD MOTOR CO.

NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured.

Fig 33: Installing Differential Housing Cover And Differential Housing Cover Bolts

Courtesy of FORD MOTOR CO.

Install the differential housing cover and the differential housing cover bolts.
- Tighten to 45 Nm (33 lb-ft).

CAUTION: For Traction-Lok® axles, first fill the axle with 118 ml (4 ounces) of friction modifier.

NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.

Fig 34: Checking Axle Lubricant Fill Level

Courtesy of FORD MOTOR CO.

Fill the axle to the level shown with axle lubricant and install the filler plug.
- Tighten to 30 Nm (22 lb-ft).