Differential Case and Ring Gear - Conventional: Assembly

WARNING: This page is about a different car, the 2012 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Lubricate the differential side gear thrust washers, wave washers and the side gear journals with axle lubricant.

Fig 1: Positioning Differential Side Gear Thrust Washers And Wave Washers On Differential Side Gears

Courtesy of FORD MOTOR CO.

Position the differential side gear thrust washers and wave washers on the differential side gears.
Install the differential side gears.

Fig 2: Installing Differential Side Gears
Courtesy of FORD MOTOR CO.

NOTE: Apply a small amount of grease to the Step Plate bore.

NOTE: If necessary, insert the Differential Gauge dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.

Assembly the Differential Gauge to the differential case.
1. Position the Differential Gauge step plate in the bottom differential side gear.
2. Position the Differential Gauge hex screw plate in the top differential side gear and hold it in place.
3. Install the Differential Gauge hex screw and tighten it 2 turns after it contacts the bottom Step Plate.
  
  Fig 3: Assembling Differential Gauge To Differential Case
  Courtesy of FORD MOTOR CO.
Use axle lubricant to lubricate the differential pinion gear thrust washers and the differential pinion gears.

Fig 4: Locating Differential Pinion Gear Thrust Washers And Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Install the differential pinion gears and differential pinion gear thrust washers opposite the differential side gears.

Fig 5: Installing Differential Pinion Gears And Differential Pinion Gear Thrust Washers
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears to align with the differential pinion shaft bore.

Fig 6: Rotating Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Install the differential pinion shaft.
- Align the hole in the differential pinion shaft with the hole in the differential case.
  
  Fig 7: Locating Differential Pinion Shaft Hole
  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.

Fig 8: Locating Differential Pinion Shaft Lock Bolt

Courtesy of FORD MOTOR CO.

Install a new differential pinion shaft lock bolt and tighten finger-tight.
Using the Differential Side Bearing Installer, install the new differential bearings on the differential case.

Fig 9: Installing Differential Bearings
Courtesy of FORD MOTOR CO.
Position the differential ring gear on the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and into the differential ring gear.
Using a shop press, press the ring gear on the differential case.
Install the 10 new differential ring gear bolts. Tighten in 2 stages.
- Stage 1: Tighten to 60 Nm (44 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 10: Locating Differential Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .