Differential Case and Ring Gear - Two-Piece, Traction-Lok®: Assembly

WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Prelubricate each clutch disc and soak the clutch friction plates in clean friction modifier.

Fig 1: Removing Clutch Disc
Courtesy of FORD MOTOR CO.

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

Fig 2: Identifying Differential Clutch Packs

Courtesy of FORD MOTOR CO.

Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.
Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the Differential Gauge.

Fig 3: Installing Differential Clutch Pack And Differential Side Gear On Gauge
Courtesy of FORD MOTOR CO.
Install the Differential Clutch Gauge on top of the differential clutch pack.

Fig 4: Positioning Differential Clutch Gauge On Top Of Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Assemble the remaining Differential Clutch Gauge and tighten the nut.
- Tighten to 6.7 Nm (60 lb-in).
  
  Fig 5: Locating Nut
  Courtesy of FORD MOTOR CO.
Use a feeler gauge and select the thickest blade that will enter between the Differential Clutch Gauge and the differential clutch pack.
- The reading will be the thickness of the new clutch shim.
  
  Fig 6: Selecting Thickest Blade Between Differential Clutch Gauge And Differential Clutch Pack
  Courtesy of FORD MOTOR CO.

NOTE: The dished or concave side of the Belleville spring must be face up and against the thrust face of the differential case.

Fig 7: Placing Selected Shim And Belleville Spring On Differential Clutch Pack

Courtesy of FORD MOTOR CO.

Place the selected shim and Belleville spring on the differential clutch pack.
Install the differential side gear and differential clutch pack into the left case half.

Fig 8: Locating Differential Side Gear
Courtesy of FORD MOTOR CO.
Position the left differential case half on the Differential Clutch Preload Gauge.

Fig 9: Positioning Left Differential Case Half On Differential Clutch Preload Gauge
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the differential pinion gears, pinion gear thrust washers and the differential pinion shaft with long-life grease.

Fig 10: Lubricating Differential Pinion Gears And Pinion Gear Thrust Washers

Courtesy of FORD MOTOR CO.

Install the differential pinion gears and thrust washers on the differential pinion shaft.
Install the differential pinion shaft and the differential pinion gears.

Fig 11: Installing Differential Pinion Shaft And Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Install the right differential clutch pack and differential side gear into the right case half.

Fig 12: Locating Differential Side Gear
Courtesy of FORD MOTOR CO.
Position the right differential case half with the index marks aligned.

Fig 13: Positioning Right Differential Case Half With Index Marks Aligned
Courtesy of FORD MOTOR CO.
Install the 6 differential case bolts.
- Tighten to 122 Nm (90 lb-ft).
  
  Fig 14: Locating Differential Case Bolts
  Courtesy of FORD MOTOR CO.
Using the Differential Clutch Preload Gauge, check the torque required to rotate one differential side gear.
- The initial break-away torque, if the 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 Differential Side Gear Rotating With Torque Specifications
  Courtesy of FORD MOTOR CO.
Install the 12 new ring gear bolts and, if removed, a new anti-lock speed sensor ring on the differential case.
- Tighten to 150 Nm (111 lb-ft).
  
  Fig 16: Pressing Wheel Speed Sensor Ring And Ring Gear On Differential Case
  Courtesy of FORD MOTOR CO.
  
  Fig 17: Locating Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .