Differential Case and Ring Gear: Assembly

Conventional differential 

NOTE: For Truetrac® and Trac-Lok® differential assemblies proceed to All differentials in this procedure.
NOTE: Use a vise with brass jaws or wood blocks.
1. Place the differential case in a vise.
2. 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.
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.
Fig 1: Installing Differential Side Gears
Courtesy of FORD MOTOR CO.
3. 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.
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.
4. Using a drift, line up the holes with those of the differential case.
5. 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.
   Fig 2: Assembling Differential Pinion Shaft And Drive On Differential Pinion Shaft To Remove Drift

   Courtesy of FORD MOTOR CO.
6. 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.
   Fig 3: Assembling Differential Pinion Shaft Lock Pin

   Courtesy of FORD MOTOR CO.

   All differentials 

NOTE: Align the tab on the anti-lock speed sensor ring with the slot in the differential case.
NOTE: Apply Threadlock® and Sealer to the new bolts.
Fig 4: Aligning Tab In Anti-Lock Speed Sensor Ring With Slot In Differential Case
Courtesy of FORD MOTOR CO.
Fig 5: Locating Bolts
Courtesy of FORD MOTOR CO.
7. Align the tab in the anti-lock speed sensor ring with the slot in the differential case. Start the two bolts through the differential case flange and into the differential ring gear to make sure the differential case and the differential ring gear bolt hole align.
8. Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
   Fig 6: Pressing Anti-Lock Speed Sensor Ring On Differential Case

   Courtesy of FORD MOTOR CO.
NOTE: Apply Threadlock® and Sealer to the new bolt threads.
Fig 7: Applying Threadlock ® And Sealer To Bolt Threads
Courtesy of FORD MOTOR CO.
9. Draw up the Grade 9 bolts alternately and evenly.
10. Install the differential bearings. Refer to Differential Case and Pinion Set Up .