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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 968 (Rear Drive Axle/Differential - Ford 10.25-Inch Ring Gear -- F150) >> Disassembly And Assembly >> Differential Case and Ring Gear - Traction-Lok® >> Assembly

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

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  1. Lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.
    Fig 1: Prelubricating Each Steel Clutch Plate
    G03878750Courtesy of FORD MOTOR CO.
    2. 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 Their Respective Differential Side Gears
    G03884593Courtesy of FORD MOTOR CO.
  2. Assemble the differential clutch packs (without the selective shims and Belleville springs) on their respective differential side gears.
  3. Clamp the special tool in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.
    Fig 3: Installing Differential Clutch Pack And Differential Side Gear On Gauge
    G03960826Courtesy of FORD MOTOR CO.
  4. Position the special tool on top of the differential clutch pack.
    Fig 4: Positioning Special Tool On Top Of Differential Clutch Pack
    G03884595Courtesy 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
    G03884596Courtesy of FORD MOTOR CO.
  6. 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
    G03960233Courtesy of FORD MOTOR CO.
    7. 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
    G03878756Courtesy of FORD MOTOR CO.
  7. 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 PART DESCRIPTION

    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
  8. 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: Placing Selective Shim And Belleville Spring On Differential Clutch Pack
    G03884599Courtesy of FORD MOTOR CO.
  9. 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
    G03960527Courtesy of FORD MOTOR CO.
    10. 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 Forcing Screw, Nut And Step Plate To Differential Case
    G03960833Courtesy of FORD MOTOR CO.
  10. Assemble the forcing screw, nut and step plate to the differential case.
    1. Position the step plate in the bottom side gear bore.
    2. Position the nut in the top side gear bore and hold it in place.
    3. Install the hex-head screw and tighten it two turns after it contacts the bottom step plate.
    11. 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
    G03960529Courtesy of FORD MOTOR CO.
  11. 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.
    12. WARNING: Keep fingers/hands away from 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
    G03960835Courtesy of FORD MOTOR CO.
  12. Inserting the special tool into the pinion shaft bore, 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 mating shaft holes are lined up exactly with the holes in the differential pinion gears.
  13. Remove the special tools.
    14. 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 And New Differential Pinion Shaft Lock Bolt Finger-Tight
    G03884604Courtesy of FORD MOTOR CO.
  14. Install the differential pinion shaft, then a new differential pinion shaft lock bolt finger-tight.
  15. Install new differential bearings.
    Fig 14: Installing New Differential Bearings
    G03884374Courtesy of FORD MOTOR CO.
  16. 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
    G03960838Courtesy of FORD MOTOR CO.
  17. Install the differential ring gear and, if removed, a new anti-lock ring.
    Fig 16: Installing Differential Ring Gear And New Anti-Lock Ring
    G03884376Courtesy of FORD MOTOR CO.
    18. NOTE: Apply stud and bearing mount to the differential ring gear bolts.
    Fig 17: Installing 12 Differential Ring Gear Bolts
    G03884368Courtesy of FORD MOTOR CO.
  18. Install the 12 differential ring gear bolts.
    • Tighten to 150 Nm (111 lb-ft).
  19. Place the differential assembly (A) in the axle housing (B).
    Fig 18: Placing Differential Assembly In Axle Housing
    G03960786Courtesy of FORD MOTOR CO.
  20. Install a differential bearing shim on the left side.
    Fig 19: Installing Differential Bearing Shim On Left Side
    G03960787Courtesy of FORD MOTOR CO.
    21. NOTE: Triangles on differential bearing cups must point outboard.
    NOTE: Apply pressure toward the left side to make sure the left differential bearing cup is seated.
    Fig 20: Installing Left Differential Bearing Cap And Loosely Install Differential Bearing Cap Bolts
    G03960788Courtesy of FORD MOTOR CO.
  21. Install the left differential bearing cap (A) and loosely install the differential bearing cap (B) bolts.
  22. Install progressively larger differential bearing shims on the right side until the largest differential bearing shim selected can be inserted by hand.
    Fig 21: Installing Progressively Larger Differential Bearing Shims On Right Side
    G03878678Courtesy of FORD MOTOR CO.
  23. Install the right side differential bearing cap and tighten the differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft)
    Fig 22: Installing Right Side Differential Bearing Cap And Tightening Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  24. Rotate the differential assembly to make sure it rotates freely.
    Fig 23: Rotating Differential Assembly
    G03878680Courtesy of FORD MOTOR CO.
    25. 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
    G03960485Courtesy of FORD MOTOR CO.
  25. Using the special tools, measure ring gear backlash.
    • Turn the ring gear without turning the pinion gear and record the measurement.
    26. 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
    G03884521Courtesy of FORD MOTOR CO.
  26. 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 AND DIFFERENTIAL BEARING SHIM SPECIFICATION

    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
    27. 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
    G03960487Courtesy of FORD MOTOR CO.
  27. To decrease ring gear backlash, install a thicker differential bearing shim (A) and a thinner differential bearing shim (B) as shown.
  28. Rotate the differential assembly several times to make sure the differential bearings are seated.
    Fig 27: Rotating Differential Assembly
    G03878680Courtesy of FORD MOTOR CO.
  29. Using the special tools, recheck the ring gear backlash.
    Fig 28: Rechecking Ring Gear Backlash Using Special Tools
    G03960485Courtesy of FORD MOTOR CO.
  30. Remove the differential bearing cap bolts (A) and differential bearing caps (B).
    Fig 29: Removing Differential Bearing Cap Bolts And Differential Bearing Caps
    G03960490Courtesy of FORD MOTOR CO.
    31. 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
    G03884389Courtesy of FORD MOTOR CO.
  31. Using the special tool, install the differential bearing shims.
  32. Install the differential bearing caps and differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 31: Installing Differential Bearing Caps And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  33. Using the special tools, recheck the backlash.
    Fig 32: Rechecking Backlash Using Special Tools
    G03960485Courtesy of FORD MOTOR CO.
  34. Install the axle shafts. For additional information, refer to AXLE SHAFT .
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