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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1145 (Rear Drive Axle/Differential - DANA 60 And 70) >> Disassembly And Assembly >> Differential Case and Ring Gear - Model 60, Limited Slip >> Assembly

Differential Case and Ring Gear - Model 60, Limited Slip: Assembly

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    NOTE: Always install an entirely new stack of clutch plates and discs on both sides if discarding one or more of the clutch plates or clutch discs or damage to the component may occur.
  1. Soak the clutch packs for 20 minutes in friction modifier.
    2. NOTE: Assemble the rear axle disc and plate kits to the differential side gears in exactly the same order as removed or damage to the component may occur.
  2. Pre-lubricate the differential side gear thrust faces and assemble the clutch plates and clutch discs onto the differential side gears.
    • Pre-lubricate each component of both stacks with rear axle lubricant or with friction modifier.
  3. Assemble the retainer clips to the clutch plate ears. Both clips must seat completely onto the clutch plate ears.
    4. Fig 1: Retainer Clips
    GF0012219Courtesy of FORD MOTOR CO.
    NOTE: Hold the rear axle disc and plate kit to keep it from falling out of the differential case.
  4. Install the rear axle disc and plate kit and differential side gear in the differential case.
    • The rear axle disc and plate kit must stay assembled to the differential side gear splines. The retainer clips must seat completely in the differential case pocket.
    5. Fig 2: Installing Rear Axle Disc & Plate Kit & Differential Side Gear In Differential Case
    GF0044686Courtesy of FORD MOTOR CO.
  5. Install the bottom differential clutch pack and differential side gear in the differential case.
    • The rear axle disc and plate kit must stay assembled to the differential side gear splines. The retainer clips must seat completely in the differential case pocket.
  6. Install the Step Plate.
    • Apply a small amount of grease to the centering hole of the Step Plate.
    7. Fig 3: Positioning Step Plate In Bottom Differential Side Gear Bore
    GF0044680Courtesy of FORD MOTOR CO.
  7. Screw the Limited Slip Preload Tool into the step plate.
    8. Fig 4: Screwing Limited Slip Preload Tool Into Step Plate
    GF0044681Courtesy of FORD MOTOR CO.
  8. Position the differential case onto the holding fixture.
    9. Fig 5: Positioning Differential Case Onto Holding Fixture
    GF0044687Courtesy of FORD MOTOR CO.
  9. Position both differential pinion gears opposite one another in the differential case. Align the differential pinion gear holes with each other. Hold the differential pinion gears in place by hand.
    10. Fig 6: Positioning Both Differential Pinion Gears Opposite One Another In Differential Case
    GF0044688Courtesy of FORD MOTOR CO.
  10. Tighten the Limited Slip Preload Tool enough so that the differential side gears move away from the differential pinion gears and relieve the loaded condition.
    11. Fig 7: Tightening Special Tool
    GF0012223Courtesy of FORD MOTOR CO.
    NOTE: Slightly loosen or tighten the Limited Slip Preload Tool to apply the necessary load to allow the differential side gears and differential pinion gears to rotate.
  11. While holding the differential pinion gears in place, insert the Rotating Handle into the differential pinion shaft bore. Rotate the differential case until the holes of both differential pinion gears align with those in the differential case.
    12. Fig 8: Inserting Rotating Handle Into Differential Pinion Shaft Bore
    GF0044682Courtesy of FORD MOTOR CO.
    NOTE: Do not overtighten the Limited Slip Preload Tool. Overtightening can damage the rear axle disc and plate kit.
  12. Tighten the Limited Slip Preload Tool enough to allow clearance to assemble the differential pinion thrust washers.
    13. Fig 9: Holding Top Differential Side Gear & Rear Axle Disc & Plate Kit In Differential Case
    GF0044683Courtesy of FORD MOTOR CO.
    NOTE: During assembly, the differential pinion thrust washer and the differential pinion gear holes must align exactly with those in the differential case.
  13. Assemble the differential pinion gear thrust washers into the differential case.
    • Use a very small screwdriver to push the washers into place.
    14. Fig 10: Using A Very Small Screwdriver To Push Washers Into Place
    GF0044689Courtesy of FORD MOTOR CO.
  14. Remove all the tools from the differential case.
  15. Install the differential pinion shaft.
    16. Fig 11: Removing Differential Pinion Shaft Using A Hammer & Drift
    GF0044679Courtesy of FORD MOTOR CO.
  16. Install the differential pinion shaft lock pin.
    17. Fig 12: Locating Differential Pinion Shaft Lock Pin
    GF0044678Courtesy of FORD MOTOR CO.
  17. If removed, install the differential ring gear.
    • Tighten the 12 Grade 9 bolts to 176 N.m (130 lb-ft).
    18. Fig 13: Locating Differential Ring Gear Bolts & Gear
    GF0044677Courtesy of FORD MOTOR CO.
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