Differential Case and Ring Gear - Conventional: Assembly

All vehicles 

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.
1. Position the differential side gear thrust washers and wave washers on the differential side gears.
2. Position the differential side gears.
   Fig 2: Identifying 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 dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.
3. 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 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.
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 4: Positioning Differential Pinion Gears
Courtesy of FORD MOTOR CO.
4. 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.
5. Engage the differential pinion gears opposite the differential side gears.
   Fig 5: Identifying Differential Pinion Gears

   Courtesy of FORD MOTOR CO.
6. Rotate the differential pinion gears to align the differential pinion shaft bore.
   Fig 6: Identifying Differential Pinion Gears To Differential Pinion Shaft Bore

   Courtesy of FORD MOTOR CO.
7. Remove the Differential Gauges after verifying the differential pinion shaft bore alignment.
8. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.
   Fig 7: Locating Differential Pinion Shaft Lock Bolt

   Courtesy of FORD MOTOR CO.
9. If removed, use the Differential Carrier Bearing Installer to install the differential bearings.
   Fig 8: Installing Differential Bearings

   Courtesy of FORD MOTOR CO.

   Electronic Locking Differential (ELD) equipped vehicles and all vehicles equipped with 3.55, 3.73, and 4.10 ratio gear sets 

NOTE: The differential flange and ring gear flange must be free of any old retaining compound material. Make sure both surfaces are clean and free of oil, dust and debris. Failure to clean the surfaces can result in ring gear runout concerns.
10. Clean all traces of the old retaining compound material from the differential flange.
    • Use solvent and Scotch-Brite® pads to remove.
11. 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 9: Identifying Bead Of Maximum Strength Retaining Compound Applying Area On Rear Face Of Ring Gear

    Courtesy of FORD MOTOR CO.

    All vehicles 

12. Install the ring gear.
    1. Place the ring gear on the differential assembly.
    2. Hand-start 3 new ring gear bolts to align the holes in the ring gear and the differential case.
    3. Using a suitable press, position the ring gear.
    4. Press the ring gear into place.
       Fig 10: Pressing Differential Ring Gear

       Courtesy of FORD MOTOR CO.
13. Hand-start the remaining 9 new differential ring gear bolts. Tighten the 12 bolts in 2 stages.
    • Stage 1: Tighten to 60 Nm (44 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 11: Locating Differential Ring Gear Bolts

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