Differential Case and Ring Gear - Traction-Lok: Assembly

WARNING: This page is about a different car, the 2013 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.

All differentials

Using friction modifier, separate the plates and lubricate each steel clutch plate. Soak all the friction plates for no less than 15 minutes.

Fig 1: Identifying Steel Clutch Plate
Courtesy of FORD MOTOR CO.

Without differential S-type clutch spring
NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.

Assemble the differential clutch packs on their respective differential side gear.

With differential S-type clutch spring
NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.

Assemble the differential clutch packs on their respective differential side gear.

Fig 2: Identifying Differential Clutch Packs And Differential Side Gears
Courtesy of FORD MOTOR CO.

All differentials
Place the base portion of the Differential Clutch Gauge in a vise. Install the differential side gear and differential clutch pack (without the shim) on the tool.

Fig 3: Installing Differential Clutch Pack And Side Gear On Tool
Courtesy of FORD MOTOR CO.
Position the Differential Clutch Gauge hand-tight on top of the differential clutch pack.

Fig 4: Identifying Special Tool 205-135
Courtesy of FORD MOTOR CO.
Install the Differential Clutch Gauge over the disc and differential clutch pack.

Fig 5: Installing Differential Clutch Gauge Over Disc
Courtesy of FORD MOTOR CO.
Install the nut.
- Tighten to 6.7 Nm (60 lb-in).
  
  Fig 6: Locating Gauge Nut
  Courtesy of FORD MOTOR CO.

NOTE: Selective shims shown in illustration are available as part of the clutch pack replacement kit.

Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. Refer to the chart to determine the correct thickness clutch shim to use.

SELECTIVE SHIMS

Feeler Gauge Thickness	Part Number	Description
0.072 - 0.080	EOAZ-4A324-G	0.025 inch
0.081 - 0.085	EOAZ-4A324-H	0.030 inch
0.086 - 0.090	EOAZ-4A324-C	0.035 inch
0.091 - 0.095	EOAZ-4A324-D	0.040 inch
0.096 - 0101	EOAZ-4A324-F	0.045 inch

Fig 7: Locating Position For Inserting Feeler Gauge Blade Between Tool And Differential Clutch Pack

Courtesy of FORD MOTOR CO.

Remove the Differential Clutch Gauge from the differential clutch pack and differential side gear assembly.
Install the shim(s) on the differential clutch pack and differential side gear assembly.

Without differential S-type clutch spring
Install the belleville washer on the clutch pack and side gear assembly with the concave side away from the clutch pack.

All differentials
Install the 2 differential side gear assemblies in the differential case.
Install the 2 differential pinion gear and differential pinion thrust washer assemblies in the differential case.

Fig 8: Installing Differential Pinion Gear And Pinion Thrust Washer
Courtesy of FORD MOTOR CO.

With differential S-type clutch spring
If equipped with a S-type clutch spring, using a soft-faced hammer, install the differential S-type clutch spring.

Fig 9: Installing Differential S-Type Clutch Spring
Courtesy of FORD MOTOR CO.

All differentials
NOTE: The pinion shaft may require to be tapped in with a soft-faced hammer.

Install the differential pinion shaft and install a new bolt finger-tight without tightening into the Loctite covered area of the bolt.

Fig 10: Locating Bolt Covered Area
Courtesy of FORD MOTOR CO.
Using the Differential Side Bearing Installer, install the 2 differential bearings.

Fig 11: Installing Differential Bearings Using Installer
Courtesy of FORD MOTOR CO.
Apply a one-eighth inch bead of maximum strength retaining compound on the rear face of the ring gear in the pattern shown in illustration.

Fig 12: Identifying Rear Face Of Ring Gear
Courtesy of FORD MOTOR CO.
Position the differential ring gear and the differential case. Align the bolt holes by starting 2 new bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.

Fig 13: Pressing Differential Ring Gear Onto Case
Courtesy of FORD MOTOR CO.
Install the 10 new differential ring gear bolts.
- Tighten to 135 Nm (100 lb-ft).
Using the Differential Clutch Gauge, check the torque required to rotate one differential side gear.
- Mount the differential assembly and Differential Clutch Gauge 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 14: Checking Torque Required To Rotate One Differential Side Gear Using Differential Clutch Gauge With Torque Specifications
  Courtesy of FORD MOTOR CO.
Install the differential carrier. Refer to DIFFERENTIAL CARRIER .