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

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Prelubricate each steel clutch plate and soak all friction plates in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.

Fig 1: Prelubricating Steel Clutch Plate
Courtesy of FORD MOTOR CO.

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

NOTE: The Belleville spring is a dished plate.

Fig 2: Assembling Differential Clutch Packs (Without Shims And Belleville Springs) On Respective Differential Side Gears

Courtesy of FORD MOTOR CO.

Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.
Clamp the bolt head of 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 (Without Shim Or The Belleville Spring) On Gauge
Courtesy of FORD MOTOR CO.
Position the special tool on top of the differential clutch pack.

Fig 4: Positioning Special Tool On Top Of Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the special tool over the disc and differential clutch pack.

Fig 5: Installing Special Tool Over Disc And Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the nut of the gauge over the top and base stud.

Fig 6: Installing Nut Of Gauge Over The Top And Base Stud
Courtesy of FORD MOTOR CO.
Use the Feeler Gauge Set 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 clutch shim. Select the correct shim size, and remove the special tools.

Fig 7: Part Number Description Chart
Courtesy of FORD MOTOR CO.

Fig 8: Identifying Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Place the shim and Belleville spring on the differential clutch pack.
- The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case.
  - Refer to the exploded view in the DESCRIPTION AND OPERATION .
    
    Fig 9: Placing Shim And Belleville Spring On Differential Clutch Pack
    Courtesy of FORD MOTOR CO.
Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case.
- Hold the upper differential clutch pack and side gear assembly in place to prevent it from falling out of the differential case.
  
  Fig 10: Inserting Differential Clutch Packs With Shims And Belleville Springs And Differential Side Gears Into Differential Case
  Courtesy of FORD MOTOR CO.

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.

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.
  
  Fig 11: Installing Hex-Head Screw
  Courtesy of FORD MOTOR CO.

NOTE: Prelubricate both sides of the differential pinion thrust washers with SAE 75W-140 High Performance Rear Axle Lubricant FITZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.

NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.

Fig 12: Positioning Differential Pinion Gears And Differential Pinion Thrust Washers In Window Of Differential Case

Courtesy of FORD MOTOR CO.

Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth.

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 13: Turning Differential Case

Courtesy of FORD MOTOR CO.

Insert the special tool into the pinion shaft bore, and 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.

CAUTION: If a new pinion shaft lock bolt is not available, use Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 and tighten to specification.

Loosen the forcing screw, and remove the Step Plate and nut from the side gear bores. Install the differential pinion shaft in the differential case.
Install a new differential pinion shaft lock bolt.

Fig 14: Installing Differential Pinion Shaft Lock Bolt
Courtesy of FORD MOTOR CO.
Replace the differential bearings, if removed.
Check the torque required to rotate one differential side gear.
- Install the special tool 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
  Courtesy of FORD MOTOR CO.
Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts.

Fig 16: Installing Ring Gear
Courtesy of FORD MOTOR CO.
Install the differential case; Refer to Differential Case .