Differential Case and Ring Gear - Traction-Lok: Assembly

WARNING: This page is about a different car, the 2014 Ford F-150. 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.

Pre-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.

Assemble the differential clutch packs (without the selective shims and Belleville spring) on the respective differential side gears.

Fig 2: Identifying Differential Clutch Packs
Courtesy of FORD MOTOR CO.
NOTE: Make sure the correct mandrel is used with the Differential Clutch Gauge.

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.

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

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

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

NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit.

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 DESCRIPTION

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

Fig 7: Locating Differential Clutch Shim

Courtesy of FORD MOTOR CO.

Remove the Differential Clutch Gauge from the clutch pack and differential side gear assembly.
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
  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 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
  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.

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.

Fig 11: Locating Differential Pinion Gear
Courtesy of FORD MOTOR CO.
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.

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.

Fig 12: Rotating Differential Case Unit
Courtesy of FORD MOTOR CO.
Remove the special tools.
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.

Install the differential pinion shaft, then a new differential pinion shaft lock bolt finger-tight.

Fig 13: Locating Differential Pinion Shaft And Bolt
Courtesy of FORD MOTOR CO.
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: Rotating Differential Side Gear
  Courtesy of FORD MOTOR CO.
Using the Differential Side Bearing Installer, install the 2 differential bearings on the differential case.

Fig 15: Installing Differential Bearings
Courtesy of FORD MOTOR CO.
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.
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
  Courtesy of FORD MOTOR CO.
Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .