Differential Carrier: Assembly

WARNING: This page is about a different car, the 2015 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

1.

NOTE: Lubricate the differential side gear thrust washers, wave washers and the side gear journals with axle lubricant.

Position the differential side gear thrust washers and wave washers on the differential side gears.

Material

: Motorcraft ® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL (WSS-M2C942-A)

Courtesy of FORD MOTOR COMPANY

2.

Position the differential side gears.

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3.

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. 1.
  
  Position the Differential Gauge step plate in the bottom differential side gear.
1. 2.
  
  Position the Differential Gauge hex screw plate in the top differential side gear and hold it in place.
1. 3.
  
  Install the Differential Gauge hex screw and tighten it 2 turns after it contacts the bottom step plate. Use Special Service Tool: 205-386 (T97T-4205-D) Gauge, Differential (Traction Lock).
  Material
  
  : Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B)

Courtesy of FORD MOTOR COMPANY

4.

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.

Material

: Motorcraft ® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL (WSS-M2C942-A)

Courtesy of FORD MOTOR COMPANY

5.

Rotate the differential pinion gears to align the differential pinion shaft bore. Remove the Differential Gauges after verifying the differential pinion shaft bore alignment.

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6.

Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.

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7.

NOTE: For 3.55 and 3.73 ratio gear sets only.

Apply a one-eighth inch bead of retaining compound on the ring gear mounting face in the pattern shown below.

Material

: Maximum Strength Retaining Compound / Loctite ® 638™ (WSK-M2G349-A8)

Courtesy of FORD MOTOR COMPANY

8.

NOTE: Tighten the ring gear bolts in a cross pattern.

Install the ring gear and the new ring gear bolts.

Torque

: Stage 1: 44 lb.ft (60 Nm) Stage 2: 90 °

Courtesy of FORD MOTOR COMPANY

9.

Using the general equipment, install the new differential bearings. Use Special Service Tool: 205-D044 (D81T-4221-A) Installer, Differential Carrier Bearing.

Courtesy of FORD MOTOR COMPANY

10.

Install the differential carrier. Refer to: Differential Carrier .