Differential Case and Ring Gear - Conventional: Notes

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.

SPECIAL TOOLS

	Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C)
	Gauge, Differential (Traction-Lock) 205-384 (T97T-4205-A)
	Gauge, Differential (Traction Lock) 205-386 (T97T-4205-D)
	Installer, Differential Side Bearing 205-010 (T57L-4221-A2)
	Remover, Differential Bearing 205-116 (T77F-4220-B1)
	Step Plate 205-D016 (D80L-630-5) or equivalent

MATERIAL SPECIFICATIONS

Item	Specification
Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL (US); CXY-75W140-1L (Canada)	WSL-M2C192-A and GL-5
Premium Long-Life Grease XG-1-C or XG-1-K (US); CXG-1-C (Canada)	ESA-M1C75-B
Threadlock and Sealer TA-25	WSK-M2G351-A5

Fig 1: Exploded View Of Differential Case And Ring Gear - Conventional

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	4236	Differential side gears
2	4228	Differential side gear thrust washers
3	-	Differential side gear wave washers
4	4215	Differential pinion gear (2 required)
5	4230	Differential pinion thrust washer (2 required)
6	4N237	Axle shaft U-washer (2 required)
7	4209	Differential ring gear
8	4241	Differential pinion shaft lock bolt
9	4211	Differential pinion shaft
10	4204	Differential case
11	4216	Differential ring gear bolt (10 required)
12	4221	Differential bearings
13	4222	Differential bearing cups

Initial disassembly

NOTE: If the differential ring gear backlash between teeth is greater than specification, remove the ring gear to check the differential case flange runout. Do not disassemble the differential carrier assembly.

Remove the differential carrier. Tag the differential shims and bearing cups for location. For additional information, refer to DIFFERENTIAL CARRIER .
Remove and discard the 10 differential ring gear bolts.

Fig 2: Locating Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.

NOTE: Care should be taken not to damage the differential ring gear bolt hole threads.

Fig 3: Inserting Punch In Differential Ring Gear Bolt Holes

Courtesy of FORD MOTOR CO.

Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.
If checking differential case flange runout, install the bearing cups in their original location and install the differential assembly.
1. Install the bearing caps and differential shims.
  - Rotate the differential assembly to verify the bearings have seated.
2. Install the Dial Indicator Gauge With Holding Fixture and record the differential case runout.
  
  Fig 4: Checking Differential Case Runout
  Courtesy of FORD MOTOR CO.
Final disassembly
Using the Differential Bearing Remover and Step Plate, remove the differential bearings.

Fig 5: Removing Differential Bearings
Courtesy of FORD MOTOR CO.
Remove the differential pinion shaft lock bolt.

Fig 6: Locating Differential Pinion Shaft Lock Bolt
Courtesy of FORD MOTOR CO.
Remove the differential pinion shaft.

Fig 7: Removing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Install the Differential Gauge in a suitable vise.

Fig 8: Installing Differential Gauge In Suitable Vise
Courtesy of FORD MOTOR CO.
Install the differential case on the Differential Gauge.

Fig 9: Installing Differential Case On Differential Gauge
Courtesy of FORD MOTOR CO.

NOTE: Apply a small amount of grease to the centering hole of the Differential Gauge.

Fig 10: Installing Differential Gauge Step Plate In Bottom Differential Side Gear

Courtesy of FORD MOTOR CO.

Install the Differential Gauge step plate in the bottom differential side gear.
Install the Differential Gauge nut in the upper differential side gear. Hold the nut in position while installing the Differential Gauge hex screw. Tighten the hex-head screw until contact is made with the Step Plate.

Fig 11: Installing Differential Gauge Nut In Upper Differential Side Gear
Courtesy of FORD MOTOR CO.
Rotate and remove the differential pinion gears and differential pinion gear thrust washers.

Fig 12: Locating Differential Pinion Gears And Differential Pinion Thrust Washer
Courtesy of FORD MOTOR CO.
Remove the differential side gears, the differential side gear washers and the differential side gear wave washers.

Fig 13: Removing Differential Side Gears And Washers
Courtesy of FORD MOTOR CO.