Differential Case: 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.

Use axle lubricant to lubricate the differential side gear thrust washer and the differential side gear journals.
- Position the differential side gear thrust washers on the differential side gears.
Fig 1: Positioning Differential Side Gear Thrust Washers On Differential Side Gears
Courtesy of FORD MOTOR CO.
Install the differential side gears.

Fig 2: Installing Differential Side Gears
Courtesy of FORD MOTOR CO.
Use axle lubricant to lubricate the differential pinion gear thrust washers and the differential pinion gears.

Fig 3: Lubricating Differential Pinion Gear Thrust Washers And Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Install the differential pinion gears and differential pinion gear thrust washers opposite the differential side gears.

Fig 4: Installing Differential Pinion Gears And Differential Pinion Gear Thrust Washers Opposite Differential Side Gears
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears to align with the differential pinion shaft bore.

Fig 5: Rotating Differential Pinion Gears To Align With Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Install the differential pinion shaft.
- Align the hole in the differential pinion shaft with the hole in the differential case.
Fig 6: Installing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.

NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer prior to installation.

Fig 7: Installing New Differential Pinion Shaft Lock Bolt

Courtesy of FORD MOTOR CO.

Install a new differential pinion shaft lock bolt.
- Tighten to 30 Nm (22 lb-ft).