Differential Case and Ring Gear - Electronic Locking Differential (ELD): 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.

All vehicles

Install the cam-ring.

Fig 1: Locating Cam-Ring
Courtesy of FORD MOTOR CO.

NOTE: Start by using the thickest thrust washers. If the gears do not assemble using the thickest thrust washers, back down in thickness until the gears will assemble.

Position the 2 LH differential side gear thrust washers and spring on the lower differential side gear and install the gear.
- Lubricate the differential side gear thrust washers and the differential side gear journals with axle lubricant.
  
  Fig 2: Locating Differential Side Gears, Differential Side Gear Thrust Washers And Spring
  Courtesy of FORD MOTOR CO.

NOTE: Start by using the thickest thrust washer. If the gears do not assemble using the thickest thrust washers, back down in thickness until the gears will assemble.

Position the differential side gear thickest thrust washer on the RH differential side gear and install the gear.
- Lubricate the differential side gear thrust washers and the differential side gear journals with axle lubricant.
Assemble the differential pinion gear thrust washers and the differential pinion gears.
- Lubricate the washers and gears with rear axle lubricant.
  
  Fig 3: Locating Differential Pinion Thrust Washers And Differential Pinion Gears
  Courtesy of FORD MOTOR CO.
Engage the differential pinion gears opposite the differential side gears.

Fig 4: Identifying Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears to align the differential pinion shaft bore.

Fig 5: Identifying Differential Pinion Gears To Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.

Fig 6: Locating Differential Pinion Shaft Lock Bolt
Courtesy of FORD MOTOR CO.

Install the Dial Indicator Gauge With Holding Fixture.

While pulling up on the RH differential gear, measure the backlash of the LH differential gear.
Backlash should be 0.001-1.000 mm (0.004-0.040 in).

If backlash is incorrect, install a thicker LH thrust washer to reduce backlash, or a thinner washer to increase backlash.

Part Number	Thickness (mm)	Thickness (in)	Quantity
Part of kit 4880	1.4	0.05	2
Part of kit 4880	1.6	0.06	2
Part of kit 4880	1.8	0.07	2

Fig 7: Measuring Backlash Of LH Differential Gear

Courtesy of FORD MOTOR CO.

Turn the differential over and reposition the Dial Indicator Gauge With Holding Fixture.

While pulling up on the LH differential gear, measure the backlash of the RH differential gear.
Backlash should be 0.001-1.000 mm (0.004-0.040 in).

If backlash is incorrect, install a thicker RH thrust washer to reduce backlash, or a thinner washer to increase backlash.

Part Number	Thickness (mm)	Thickness (in)	Quantity
Part of kit 4880	1.1	0.04	1
Part of kit 4880	1.3	0.05	1
Part of kit 4880	1.5	0.06	1

Fig 8: Measuring Backlash Of RH Differential Gear

Courtesy of FORD MOTOR CO.

Tighten the differential pinion shaft lock bolt to 30 Nm (22 lb-ft).
Install the plunger assembly.

Fig 9: Locating Plunger Assembly
Courtesy of FORD MOTOR CO.
Install the ELD coil, 3 new stoppers and 6 new screws that hold the coil in place.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 10: Locating Screws And Stoppers
  Courtesy of FORD MOTOR CO.
Use the Differential Carrier Bearing Installer to install the 2 differential bearings.

Fig 11: 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.

Clean all traces of the old retaining compound material from the differential flange.
- Use solvent and Scotch-Brite® pads to remove.
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 Bead Of Maximum Strength Retaining Compound Applying Area On Rear Face Of Ring Gear
Courtesy of FORD MOTOR CO.

All vehicles
Install the ring gear and the 12 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 13: Locating Differential Ring Gear Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Install the differential with the tabs on the ELD coil up against the differential bearing cap mounting surface.

Fig 14: Locating Differential With Tabs On ELD Coil

Courtesy of FORD MOTOR CO.

Install the differential carrier in the axle housing. For additional information, refer to DIFFERENTIAL CARRIER .