Differential Case: 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.

Lubricate the differential side gear thrust washers and the differential side gear journals with axle lubricant.
Position the differential side gear thrust washers on the differential side gears.

Fig 1: Locating Differential Side Gears And Differential Side Gear Thrust Washers
Courtesy of FORD MOTOR CO.
Position the differential side gears.

Fig 2: Positioning Differential Side Gears
Courtesy of FORD MOTOR CO.
Lubricate the differential pinion thrust washers and the differential pinion gears with axle lubricant and assemble them.

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: Engaging Differential Pinion Gears Opposite Differential Side Gears
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears to align with the differential pinion shaft bore.

Fig 5: Rotating Differential Pinion Gears To Align With Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Insert the differential pinion shaft.

Fig 6: Inserting Differential Pinion Shaft
Courtesy of FORD MOTOR CO.

NOTE: If a new pinion shaft bolt is unavailable, coat the threads with sealer.

Install a new differential pinion shaft bolt.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 7: Locating Differential Pinion Shaft Bolt
  Courtesy of FORD MOTOR CO.
Install the differential ring gear.
1. Place the differential ring gear on the differential assembly.
2. Hand-start 3 ring gear bolts to align the holes in the differential ring gear and the differential assembly.
3. Place the differential carrier and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
4. Press the differential ring gear into place.
  
  Fig 8: Installing Differential Ring Gear
  Courtesy of FORD MOTOR CO.
Install the 7 remaining new bolts.
- Tighten all 10 bolts to 128 Nm (95 lb-ft).
  
  Fig 9: Locating Differential Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .