Differential Case and Ring Gear - Conventional: Assembly

All axles 

NOTE: Use a vise with brass jaws or wood blocks.
1. Place the differential case in a vise.
2. Apply grease to the new differential side gear thrust washers and to the thrust face of the new differential side gears.
3. Apply grease to the new differential pinion thrust washers and the new differential pinion gears.
4. Lubricate the differential side gears and differential pinion gears with the specified lubricant.
Fig 1: Differential Side Gear & Thrust Washer
Courtesy of FORD MOTOR CO.
5. Assemble both differential side gears and differential side gear thrust washers. Hold the assembly in place by hand, then assemble the differential pinion gears and differential side gear thrust washers to hold the differential side gears in place.
NOTE: Rotate the differential side gears until the holes of the differential side gear thrust washers and the differential pinion gears line up with the holes of the differential case. If the differential pinion gears cannot be rotated 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.
6. Using a drift, line up the holes with those of the differential case.
7. Assemble the differential pinion shaft and drive on the differential pinion shaft to remove the drift. Align the lock pin hole of the differential pinion shaft with the lock pin hole of the differential case.
Fig 2: Installing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.

Full-float axles 

8. 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 in place. Note the location of the slot in the differential pinion shaft lock pin and peen 90 degrees away.
Fig 3: Peening Case Over Differential Pinion Shaft Lock Pin
Courtesy of FORD MOTOR CO.

Semi-float axles 

NOTE: The semi-float axle differential assembly is equipped with either a Loctite® coated differential pinion shaft lock screw or a differential pinion shaft lock screw with torque prevailing threads. The Loctite® treated differential pinion shaft lock screw has a 5/32-in hexagram socket head. Never, under any circumstance, reuse a Loctite® coated screw after removing it. Always discard the screw and install a new one. The torque prevailing differential pinion shaft lock screw has a 12-point drive head. This type of screw is reusable for no more than 4 installations. When in doubt of the number of installations of a torque prevailing differential pinion shaft lock screw, discard it and install a new one or damage to the component may occur.
9. Install the pinion shaft and pinion shaft lock screw finger tight to prevent the differential side gears and differential pinion gears from rotating and falling out of the differential case.

All axles 

10. Start the 2 ring gear bolts through the differential case flange into the ring gear to make sure the differential case and the ring gear bolt hole align.
Fig 4: Locating Ring Gear Bolts On Differential Case Flange
Courtesy of FORD MOTOR CO.
11. Apply threadlock to the 12 new ring gear bolts.
12. Install and tighten the Grade 9 ring gear bolts alternately and evenly.
    • Tighten to 176 Nm (130 lb-ft).
Fig 5: Locating Ring Gear Bolts
Courtesy of FORD MOTOR CO.
13. Install the differential bearings. For additional information, refer to Differential Bearings - Dana 60  or Differential Bearings - Dana 70  .
14. Install the differential carrier. For additional information, refer to Differential Carrier - Dana 60  or Differential Carrier - Dana 70 .