Differential Case and Ring Gear: Assembly

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.

Install selective shims on the clutch pack and the 2 differential side gear assemblies.
Install the 2 differential side gears in the differential case.

Fig 1: Identifying Differential Side Gears

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Install the 2 differential pinion gears with the 2 differential pinion gear thrust washers in the differential case.

Fig 2: Identifying Differential Pinion Gears

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

Fig 3: Installing Differential Clutch Spring

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

Fig 4: Install A New Differential Pinion Shaft Lock Bolt

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Using the special tool, install the 2 differential bearings on the differential case.
1. Position the differential bearings.
2. Using the special tool, press on the differential bearings.

Fig 5: Installing Differential Bearings

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Press the differential ring gear on the differential assembly.
Install the 10 new differential ring gear bolts.
- Tighten to 105 Nm (77 lb-ft).

Fig 6: Identifying Differential Ring Gear Bolts

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Using the special tools, check the torque required to rotate one differential side gear.
- Mount the differential assembly 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 7: Mounting Differential Assembly & Special Tool 205-022 In A Vise

Courtesy of FORD MOTOR CO.

Install the differential carrier. For additional information, refer to Differential Carrier .