Differential Case and Ring Gear - Conventional: Assembly

WARNING: This page is about a different car, the 2008 Ford Pickup and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Use a vise with brass jaws or wood blocks.

Place the differential case in a vise.

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.

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 with the differential pinion gear thrust washers to hold the differential side gears in place.

Fig 1: Differential Side Gear & Thrust Washer

Courtesy of FORD MOTOR CO.

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.

Using a suitable tool, line up the holes with those of the differential case.
Position the differential pinion shaft. Align the lock pin hole in the differential pinion shaft with the lock pin hole in the differential case.
Assemble the differential pinion shaft lock pin. Peen the metal of the differential case over the differential pinion shaft lock pin in 2 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 2: Peening Case Over Differential Pinion Shaft Lock Pin

Courtesy of FORD MOTOR CO.

NOTE: Apply threadlock to the 2 new differential ring gear bolts.

NOTE: If removed, install the anti-lock speed sensor ring.

Start 2 bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and the differential case align.

Fig 3: Identifying Bolts In Differential Case Flange, Anti-Lock Sensor Ring & Differential Ring Gear

Courtesy of FORD MOTOR CO.

Press the differential ring gear on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.

Fig 4: Pressing Anti-Lock Speed Sensor Ring

Courtesy of FORD MOTOR CO.

Apply threadlock and install the 10 remaining bolts alternately and evenly.
- Tighten to 298 Nm (220 lb-ft).

Fig 5: Identifying Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Using the Differential Carrier Bearing Installer, install the differential bearing and shim on the LH side of the differential case.

Fig 6: Identifying Special Tool (205-D044) For Differential Bearing Installation

Courtesy of FORD MOTOR CO.

Using the Differential Carrier Bearing Step Plate and Differential Carrier Bearing Installer, install the differential bearing.
1. Place the Differential Carrier Bearing Step Plate on the differential bearing to protect it during the installation of the opposite bearing.
2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.

Fig 7: Using Special Tools (205-432, 205-D044) To Install Differential Bearing Onto Hub

Courtesy of FORD MOTOR CO.

Assemble the new differential bearing cups to the new differential bearings.
Install the differential carrier. For additional information, refer to Differential Carrier .