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Home >> Ford >> 2012 >> Mustang Base, 2D Coupe, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 141 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear -- F150) >> Disassembly And Assembly >> Differential Case and Ring Gear - Traction-Lok >> Assembly

Differential Case and Ring Gear - Traction-Lok: 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: Use 118 ml (4 oz) of the specified friction modifier in the axle.
    Fig 1: Identifying Steel Clutch Plate
    G06125304Courtesy of FORD MOTOR CO.
  1. Pre-lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.
    2. NOTE: Do not mix the differential clutch packs or selective shims from one side with the other.
    NOTE: The Belleville spring is a dished plate.
    Fig 2: Assembling Differential Clutch Packs On Differential Side Gears
    G06166902Courtesy of FORD MOTOR CO.
  2. Assemble the differential clutch packs (without the selective shims and Belleville spring) on the respective differential side gears.
    3. NOTE: Make sure the correct mandrel is used with the Differential Clutch Gauge.
    Fig 3: Installing Differential Clutch Pack And Differential Side Gear
    G06166903Courtesy of FORD MOTOR CO.
  3. Place the base portion of the Differential Clutch Gauge in a vise. Install the differential clutch pack and differential side gear (without the selective shim or Belleville spring) on the gauge.
  4. Position the Differential Clutch Gauge hand-tight on top of the differential clutch pack.
    Fig 4: Positioning Differential Clutch Gauge Hand-Tight On Top Of Differential Clutch Pack
    G06166904Courtesy of FORD MOTOR CO.
  5. Install the Differential Clutch Gauge over the disc and differential clutch pack.
    Fig 5: Installing Differential Clutch Gauge Over Disc And Differential Clutch Pack
    G06166905Courtesy of FORD MOTOR CO.
  6. Install the nut of the gauge over the top and base stud.
    • Tighten to 7 Nm (62 lb-in).
      Fig 6: Installing Nut Of Gauge Over Top And Base Stud
      G06166906Courtesy of FORD MOTOR CO.
    7. NOTE: Selective shims shown in illustration are available as part of the Clutch Pack Replacement Kit.
    Fig 7: Inserting Feeler Gauge Between Tool And Differential Clutch Pack
    G06166907Courtesy of FORD MOTOR CO.
  7. Use the feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack. Refer to the chart to determine which shim to use.
    SELECTIVE SHIMS

    Feeler Gauge Part Number Description
    0.096-0.104 E0AZ-4A324-G 0.025 in
    0.105-0.109 E0AZ-4A324-H 0.030 in
    0.110-0.114 E0AZ-4A324-C 0.035 in
    0.115-0.190 E0AZ-4A324-D 0.040 in
    0.120-0.125 E0AZ-4A324-F 0.045 in
  8. Remove the Differential Clutch Gauge from the clutch pack and differential side gear assembly.
  9. Place the selective shim and Belleville spring on the differential clutch pack.
    • The dished or concave side of the Belleville spring must face up against the thrust face of the differential case.
      Fig 8: Locating Selective Shim And Belleville Spring
      G06125305Courtesy of FORD MOTOR CO.
  10. Install the differential side gears with the differential clutch packs, selective shims and Belleville spring into the differential case.
    • Hold the differential side gear assembly in place to prevent it from falling out of the differential case.
      Fig 9: Installing Differential Side Gears With Differential Clutch Packs, Selective Shims And Belleville Spring
      G06452480Courtesy of FORD MOTOR CO.
    11. NOTE: Apply a small amount of grease to the step plate bore.
    NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.
  11. Assemble 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 in the top differential side gear and hold it in place.
    3. Install the Differential Gauge and tighten it 2 turns after it contacts the bottom step plate.
      Fig 10: Assembling Differential Gauge To Differential Case
      G06166868Courtesy of FORD MOTOR CO.
    12. NOTE: Lubricate both sides of the differential pinion gear thrust washers with axle lubricant.
    NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.
    Fig 11: Locating Differential Pinion Gears And Differential Pinion Gear Thrust Washers
    G06167146Courtesy of FORD MOTOR CO.
  12. Position the differential pinion gears and differential pinion gear thrust washers in the window of the differential case so they mesh with the differential side gear teeth.
    13. NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.
    Fig 12: Inserting Differential Rotator Into Pinion Shaft Bore And Differential Case
    G06167147Courtesy of FORD MOTOR CO.
  13. Inspect the Differential Rotator into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gear and "walk" into the differential case. Rotate the differential case until the pinion shaft mating holes are lined up exactly with the holes in the differential pinion gears.
  14. Remove the special tools.
    15. NOTE: If a new differential pinion shaft lock bolt is unavailable, coat the threads of the original differential pinion shaft lock bolt with threadlock prior to installation.
    Fig 13: Locating Differential Pinion Shaft And Bolt
    G06125310Courtesy of FORD MOTOR CO.
  15. Install the differential pinion shaft, then a new differential pinion shaft lock bolt finger-tight.
  16. 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: Turning Differential Side Gear
      G06184963Courtesy of FORD MOTOR CO.
  17. Using the Differential Side Bearing Installer, install the 2 differential bearings on the differential case.
    Fig 15: Installing Differential Bearings On Differential Case
    G06166915Courtesy of FORD MOTOR CO.
  18. Position the differential ring gear and the differential case. Align the bolt holes by hand-starting 2 new bolts through the holes in the differential case and into the differential ring gear.
  19. Hand-start the 8 remaining new differential ring gear bolts. Tighten the 10 bolts in 2 stages.
    • Stage 1: Tighten to 60 Nm (44 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 16: Locating Differential Ring Gear Bolts
      G06125372Courtesy of FORD MOTOR CO.
  20. Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER  .
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