Dana Model S130 Conventional Wheel Differential Assembly, Disassembled View: Assembly

All axles 

1. If removed, install a new anti-lock speed sensor ring with a dead blow hammer.
   Fig 1: Identifying Anti-Lock Speed Sensor Ring

   Courtesy of FORD MOTOR CO.

   S110 axles 

2. Install the inner side gear thrust washer and inner side gear.
   Fig 2: Identifying Inner Side Gear And Thrust Washer

   Courtesy of FORD MOTOR CO.
3. Align the pinion gear cross shaft with the pin hole vertical position.
   Fig 3: Identifying Pinion Cross Shaft

   Courtesy of FORD MOTOR CO.
4. Install the first pinion gear thrust washer and pinion gear on the pinion cross shaft.
   NOTE: Lightly lubricate all of the mating surfaces with clean axle lubricant. This will aid in assembly and provide initial lubrication.
   Fig 4: Identifying First Pinion Gear Thrust Washer, Pinion Gear And Pinion Cross Shaft

   Courtesy of FORD MOTOR CO.
5. Install the second pinion gear and pinion gear thrust washer on the differential cross shaft.
   Fig 5: Installing Second Pinion Gear And Pinion Gear Thrust Washer

   Courtesy of FORD MOTOR CO.
6. Install the differential cross shaft lockpin.
   Fig 6: Locating Differential Cross Shaft Lockpin

   Courtesy of FORD MOTOR CO.
7. NOTE: There is no thrust washer in this location.

   Install the outer side gear.

   Fig 7: Identifying Side Gear

   Courtesy of FORD MOTOR CO.
8. Align the ring gear and the differential case bolt holes. Install the 12 NEW ring gear bolts in the holes finger-tight.
   Fig 8: Identifying Ring Gear Bolts

   Courtesy of FORD MOTOR CO.

   S130 axles 

9. Install the inner side gear thrust washer and inner side gear.
   NOTE: Lubricate both sides of the thrust washer with axle lubricant.
   Fig 9: Identifying Inner Side Gear And Thrust Washer

   Courtesy of FORD MOTOR CO.
10. Position the full shaft pinion shaft in the shaft bores of the pinion case. Make sure it is the side that does not have lockpin holes.
    1. Locate the lockpin holes.
    2. Position the side pinion and thrust washer.
    3. Start the full shaft into the differential case.
       Fig 10: Positioning Full Shaft Pinion Shaft In Shaft Bores Of Pinion Case

       Courtesy of FORD MOTOR CO.
11. Install the opposite side pinion and washer.
    1. Position the thrust washer and pinion.
    2. Push the shaft through the pinion and washer.
       Fig 11: Installing Opposite Side Pinion And Washer

       Courtesy of FORD MOTOR CO.
12. Install a side pinion and thrust washer on the halfshaft side.
    1. Position the side pinion and thrust washer.
       Fig 12: Installing Side Pinion And Thrust Washer On Halfshaft Side

       Courtesy of FORD MOTOR CO.
13. Install the halfshaft so the pin is facing upward and push the shaft in until it stops.
    Fig 13: Installing Halfshaft

    Courtesy of FORD MOTOR CO.
14. Position the halfshaft in the case.
    1. Align the halfshaft in the slot.
    2. Align the lockpin hole with the halfshaft.
       Fig 14: Identifying Halfshaft Slot And Lockpin Hole

       Courtesy of FORD MOTOR CO.
15. Install the lockpin.
    Fig 15: Installing Locking Pin

    Courtesy of FORD MOTOR CO.
16. Repeat Steps  6 and  7 to install the opposite halfshaft.
17. NOTE: There is no thrust washer in this location.

    Install the outer side gear.

    Fig 16: Identifying Side Gear

    Courtesy of FORD MOTOR CO.
18. Remove the locating dowels from the ring gear.
    Fig 17: Removing Locating Dowels From Ring Gear

    Courtesy of FORD MOTOR CO.
19. Install the dowels over the lockpins.
    Fig 18: Installing Dowels Over Locking Pins

    Courtesy of FORD MOTOR CO.
20. Lower the ring gear on the case aligning the locking dowels.
    Fig 19: Lowering Ring Gear On Case

    Courtesy of FORD MOTOR CO.
21. Install the 12 new ring gear bolts finger-tight.
    Fig 20: Identifying Ring Gear Bolts

    Courtesy of FORD MOTOR CO.

    All axles 

22. Using the Step Plate and a press, install the differential assembly half on the ring gear half.
    Fig 21: Installing Differential Assembly Half On Ring Gear Half

    Courtesy of FORD MOTOR CO.
23. Tighten the 12 new ring gear bolts.
    • Tighten to 203 Nm (150 lb-ft).
      Fig 22: Locating Ring Gear Bolts

      Courtesy of FORD MOTOR CO.
24. Using the Wheel Speed Sensor Ring Installer and a suitable press, install the ring gear side carrier bearing.
    Fig 23: Installing Ring Gear Side Carrier Bearing

    Courtesy of FORD MOTOR CO.
25. Using the Wheel Speed Sensor Ring Installer and a suitable press, install the differential side carrier bearing.
    Fig 24: Installing Differential Side Carrier Bearing

    Courtesy of FORD MOTOR CO.
26. Carefully position the differential assembly into the carrier housing.
27. NOTE: The bearing cups must seat on the differential side bearings.
    NOTE: Align the match marks.
    NOTE: The bolt threads must be clean.

    Install the differential bearing caps.

    1. Position the bearing cap onto the leg.
    2. Apply threadlock to the bolt threads, and install the bolts.
       • Tighten the bolts enough to eliminate visible space between the bearing cap and leg. Do not tighten the bolts at this time.
         Fig 25: Identifying Differential Bearing Cap And Bolts

         Courtesy of FORD MOTOR CO.
28. NOTE: Align the differential assembly within the bearing bores before applying preload or damage to the bearings will result.

    Install the differential bearing adjusting rings.

    • Tighten both adjusting rings until there is zero end play and some backlash between the differential ring gear and pinion. Make sure the adjusting ring tooth aligns so that installation of the adjusting ring cotter pin is possible.
      Fig 26: Installing Differential Bearing Adjusting Rings

      Courtesy of FORD MOTOR CO.
29. Using the Dial Indicator Gauge with Holding Fixture, set the backlash at zero.
    • NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.

      Loosen the adjusting ring on the tooth side of the differential ring gear one tooth and tighten the opposite adjusting ring one tooth. Repeat this process until backlash is at zero.

      Fig 27: Measuring Differential Ring Gear And Pinion Backlash

      Courtesy of FORD MOTOR CO.
30. Using the Dial Indicator Gauge with Holding Fixture, set the backlash and the bearing preload to specifications.
    • With a new matched set installed, set the backlash to the specification.
    • With the original matched set installed, set the backlash to the specification recorded prior to disassembly.
    • NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.

      Tighten the adjusting ring on the tooth side of the differential ring gear until backlash is within specifications.

      Fig 28: Measuring Differential Ring Gear And Pinion Backlash

      Courtesy of FORD MOTOR CO.
31. Using the Dial Indicator Gauge with Holding Fixture, check the differential ring gear and pinion backlash in 4 equally spaced positions around the differential ring gear.
    • The acceptable backlash tolerance is ±0.0508 mm (0.002 in) from the backlash specification.
    • If the backlash tolerance varies more than 0.080 mm (0.003 in) between the 4 positions, remove the differential and determine the cause.
      Fig 29: Measuring Differential Ring Gear And Pinion Backlash

      Courtesy of FORD MOTOR CO.
32. Check the differential ring gear and pinion backlash, as described in the previous step, after tightening the differential bearing cap bolts.
    • Tighten to 190 Nm (140 lb-ft).
      Fig 30: Locating Differential Bearing Cap Bolts

      Courtesy of FORD MOTOR CO.
33. Install the adjusting ring cotter pins.
    Fig 31: Locating Adjusting Ring Cotter Pins

    Courtesy of FORD MOTOR CO.
34. Install the rear wheel speed sensor and bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 32: Locating Rear Wheel Speed Sensor And Bolt

      Courtesy of FORD MOTOR CO.
35. Install the carrier. For additional information, refer to DIFFERENTIAL CARRIER .