Differential Case and Ring Gear - Traction-Lok®: Assembly

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Friction Plates & Friction Modifier

Courtesy of FORD MOTOR CO.

NOTE: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the axle.

Pre-lubricate each steel clutch plate and soak all friction plates with additive friction modifier for at least 15 minutes.

Fig 2: Identifying Differential Clutch Packs (Without Selective Shims)

Courtesy of FORD MOTOR CO.

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

Assemble the differential clutch packs (without the shims) on the respective differential side gears.

Fig 3: Installing Differential Clutch Pack & Differential Side Gear On Gauge

Courtesy of FORD MOTOR CO.

NOTE: Make sure the correct mandrel is used with the special tool.

Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge.

Fig 4: Positioning Special Tool (205-135) On Differential Clutch Pack

Courtesy of FORD MOTOR CO.

Position the special tool hand-tight on top of the differential clutch pack.

Fig 5: Installing Special Tool (205-135) Over Disc & Differential Clutch Pack

Courtesy of FORD MOTOR CO.

Install the special tool over the disc and clutch pack.

Fig 6: Locating Differential Clutch Pack Nut

Courtesy of FORD MOTOR CO.

Install the nut of the special tool over the top and base stud.
- Tighten to 6.7 Nm (60 lb-in).

Fig 7: Locating Differential Clutch Pack & Clutch Shim

Courtesy of FORD MOTOR CO.

Use a suitable feeler gauge 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.

SELECTIVE SHIMS

Part Number	Description
E4DZ-4A324-G	0.025 inch
E4DZ-4A324-H	0.030 inch
E4DZ-4A324-C	0.035 inch
E4DZ-4A324-D	0.040 inch
E4DZ-4A324-F	0.045 Inch

Remove the special tool from the clutch pack and side gear assembly.
Install shims on the clutch pack and side gear assembly.

Fig 8: Identifying Differential Side Gears In Differential Case

Courtesy of FORD MOTOR CO.

Install the differential side gears in the differential case.

Fig 9: Identifying Differential Pinion Gears

Courtesy of FORD MOTOR CO.

Install the differential pinion gears with differential pinion thrust washers in the differential case.

Fig 10: Installing Differential Clutch Spring

Courtesy of FORD MOTOR CO.

Using a soft-faced hammer, install the differential clutch spring.

Fig 11: Installing New Differential Pinion Shaft Lock Bolt

Courtesy of FORD MOTOR CO.

NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with threadlock and sealer prior to installation.

Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight.

Fig 12: Checking Rotational Torque Using Special Tool (205-022)

Courtesy of FORD MOTOR CO.

Check the torque required to rotate one differential side gear.
- Mount the differential case and special tool in a vise.
- The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.

Fig 13: Identifying Special Tools (205-009)

Courtesy of FORD MOTOR CO.

Using the special tool, install the differential bearing on the differential case. Repeat for the other side.

Fig 14: Pressing Differential Ring Gear On Differential Case

Courtesy of FORD MOTOR CO.

Press the new anti-lock speed sensor ring and the ring gear on the differential case.

Fig 15: Identifying Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Install the 10 new ring gear bolts.
- Tighten to 105 Nm (77 lb-ft).
Install the differential case. For additional information, refer to Differential Carrier .