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: Use 118 ml (4 oz) of the friction modifier in the axle.

Lubricate each steel clutch plate and soak all the friction plates for no less than 15 minutes with friction modifier.

Fig 2: Identifying Differential Clutch Packs And Differential Side Gears

Courtesy of FORD MOTOR CO.

NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.

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

Fig 3: Installing Differential Clutch Pack & Differential Side Gear Using Special Tool (205-270)

Courtesy of FORD MOTOR CO.

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

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 differential clutch pack.

Fig 6: Locating Differential Clutch Pack Nut

Courtesy of FORD MOTOR CO.

Install the nut.
- Tighten to 6.7 Nm (60 lb-in).

Fig 7: Locating Thickest Blade

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Select and insert the thickest feeler gauge 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
EOAZ-4A324-G	0.025 inch
EOAZ-4A324-H	0.030 inch
EOAZ-4A324-C	0.035 inch
EOAZ-4A324-D	0.040 inch
EOAZ-4A324-F	0.045 inch

Remove the special tool from the differential clutch pack and differential side gear assembly.
Install the shim(s) on the differential clutch pack and differential side gear assembly.

Fig 8: Identifying Differential Side Gears

Courtesy of FORD MOTOR CO.

Install the differential side gear assemblies in the differential case.

Fig 9: Identifying Differential Pinion Gears

Courtesy of FORD MOTOR CO.

Install the differential pinion gear and differential pinion thrust washer assemblies 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 bolt is unavailable, coat the threads with threadlock prior to installation.

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

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

Courtesy of FORD MOTOR CO.

Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
- If reusing the original clutch plates, the initial minimum break-away torque must be no less than the specification. The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary.

Fig 13: Using Special Tool (205-010) To Install Differential Bearings

Courtesy of FORD MOTOR CO.

Using the special tool, install the differential bearings.
Position the differential ring gear, the anti-lock speed sensor ring and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case.

Fig 14: Identifying Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

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