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.

All vehicles

Lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15 minutes.

Fig 1: Identifying Steel Clutch Plate
Courtesy of FORD MOTOR CO.

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

Courtesy of FORD MOTOR CO.

Assemble the differential clutch packs (without the selective shims and Belleville springs) on their respective differential side gears.
Clamp the bolt head of the Differential Gauge in a vise. Install the differential clutch pack and the differential side gear (without the selective shim or the Belleville spring) on the Differential Gauge.

Fig 3: Installing Differential Clutch Pack And Differential Side Gear
Courtesy of FORD MOTOR CO.
Position the Differential Clutch Gauge on top of the differential clutch pack.

Fig 4: Positioning Differential Clutch Gauge On Top Of Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the Differential Gauge over the disc and differential clutch pack.

Fig 5: Installing Differential Gauge Over Disc And Differential Clutch Pack
Courtesy of FORD MOTOR CO.
Install the nut over the top and base stud.
- Tighten to 7 Nm (62 lb-in).
  
  Fig 6: Locating Nut Over Top And Base Stud
  Courtesy of FORD MOTOR CO.

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

Courtesy of FORD MOTOR CO.

Use the feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack. Subtract 0.0075" from the reading, Then select the closest thinner thickness selective shim, that will be the new selective shim that should be used.
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
  Courtesy of FORD MOTOR CO.
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
  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.

Assemble the Differential Gauge to the differential case.
1. Position the Differential Gauge 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
  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 11: Positioning Differential Pinion Gears

Courtesy of FORD MOTOR CO.

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.

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: Rotating Differential Case

Courtesy of FORD MOTOR CO.

Insert 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 gears 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.
Remove the Differential Gauge.
Install the 2 new differential bearings using the Differential Carrier Bearing Installer.

Fig 13: Installing Differential Bearings
Courtesy of FORD MOTOR CO.
Check the torque required to rotate one differential side gear.
- Install the Differential Gauge with the 1/2-inch drive hole as shown in illustration.
- The initial break-away torque, if original clutch plates are used, must be at least the minimum specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.
  
  Fig 14: Checking Differential Side Gear Torque
  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 15: Identifying Bead Of Maximum Strength Retaining Compound Applying Area On Rear Face Of Ring Gear
Courtesy of FORD MOTOR CO.

All vehicles
Using a suitable press, install the differential ring gear.

Fig 16: Installing Differential Ring Gear
Courtesy of FORD MOTOR CO.
Install the new 12 differential ring gear bolts.
- Tighten to 150 Nm (111 lb-ft).
  
  Fig 17: Locating Differential Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .