Differential Case And Ring Gear: Assembly

All axles 

1. If removed, install a new anti-lock speed sensor ring with a dead blow hammer.
Fig 1: Identifying Anti-Lock Speed Sensor Ring
Courtesy of FORD MOTOR CO.

S110 axles 

2. Install the inner side gear thrust washer and inner side gear.
Fig 2: Identifying Inner Side Gear And Thrust Washer
Courtesy of FORD MOTOR CO.
3. Align the pinion gear cross shaft with the pin hole vertical position.
Fig 3: Identifying Pinion Cross Shaft
Courtesy of FORD MOTOR CO.
NOTE: Lightly lubricate all of the mating surfaces with clean axle lubricant. This will aid in assembly and provide initial lubrication.
4. Install the first pinion gear thrust washer and pinion gear on the pinion cross shaft.
Fig 4: 1st Pinion Gear Thrust Washer And Pinion Gear On Pinion Cross Shaft
Courtesy of FORD MOTOR CO.
5. Install the second pinion gear and pinion gear thrust washer on the differential cross shaft.
Fig 5: 2nd Pinion Gear And Pinion Gear Thrust Washer
Courtesy of FORD MOTOR CO.
6. Install the differential cross shaft lock pin.
Fig 6: Locating Differential Pinion Cross Shaft Lock Pin
Courtesy of FORD MOTOR CO.
NOTE: There is no thrust washer in this location.
7. Install the outer side gear.
Fig 7: Identifying Outer Side Gear
Courtesy of FORD MOTOR CO.
8. Align the ring gear and the differential case bolt holes. Install the 12 ring gear bolts in the holes finger tight.
Fig 8: Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.

S130 axles 

NOTE: Lubricate both sides of the thrust washer with axle lubricant.
9. Install the inner side gear thrust washer and inner side gear.
Fig 9: Identifying Inner Side Gear And Thrust Washer
Courtesy of FORD MOTOR CO.
10. Position the full shaft pinion shaft in the shaft bores of the pinion case. Make sure it is the side that does not have lock pin holes.
    1. Locate the lock pin holes.
    2. Position the side pinion and thrust washer.
    3. Start the full shaft into the differential case.
Fig 10: Positioning Full Shaft Pinion Shaft In Shaft Bores Of Pinion Case
Courtesy of FORD MOTOR CO.
11. Install the opposite side pinion and washer.
    1. Position the thrust washer and pinion.
    2. Push the shaft through the pinion and washer.
Fig 11: Installing Full Shaft Pinion Shaft Opposite Side Of Pinion And Washer
Courtesy of FORD MOTOR CO.
12. Install a side pinion and thrust washer on the halfshaft side.
    1. Position the side pinion and thrust washer.
Fig 12: Installing Side Pinion And Thrust Washer On Halfshaft Side
Courtesy of FORD MOTOR CO.
13. Install the halfshaft so the pin is facing upward and push the shaft in until it stops.
Fig 13: Installing Halfshaft
Courtesy of FORD MOTOR CO.
14. Position the halfshaft in the case.
    1. Align the halfshaft in the slot.
    2. Align the lock pin hole with the halfshaft.
Fig 14: Aligning Halfshaft In Slot
Courtesy of FORD MOTOR CO.
15. Install the lock pin.
Fig 15: Installing Lock Pin
Courtesy of FORD MOTOR CO.
16. Repeat Steps 6 and 7 to install the opposite halfshaft.
NOTE: There is no thrust washer in this location.
17. Install the outer side gear.
Fig 16: Identifying Outer Side Gear
Courtesy of FORD MOTOR CO.
18. Remove the locating dowels from the ring gear.
Fig 17: Removing Locating Dowels From Ring Gear
Courtesy of FORD MOTOR CO.
19. Install the dowels over the lock pins.
Fig 18: Installing Dowels Over Locking Pins
Courtesy of FORD MOTOR CO.
20. Lower the ring gear on the case aligning the locking dowels.
Fig 19: Lowering Ring Gear On Case
Courtesy of FORD MOTOR CO.
21. Install the 12 ring gear bolts finger tight.
Fig 20: Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.

All axles 

22. Using the Step Plate and a press, install the differential assembly half on the ring gear half.
Fig 21: Installing Differential Assembly Half On Ring Gear Half
Courtesy of FORD MOTOR CO.
23. Tighten the 12 ring gear bolts.
    • Tighten to 203 Nm (150 lb-ft).
Fig 22: Installing Ring Gear Bolts
Courtesy of FORD MOTOR CO.
24. Using the Wheel Speed Sensor Ring Installer and a suitable press, install the ring gear side carrier bearing.
Fig 23: Installing Ring Gear Side Carrier Bearing
Courtesy of FORD MOTOR CO.
25. Using the Wheel Speed Sensor Ring Installer and a suitable press, install the differential side carrier bearing.
Fig 24: Installing Differential Side Carrier Bearing
Courtesy of FORD MOTOR CO.
26. Carefully position the differential assembly into the carrier housing.
NOTE: The bearing cups must seat on the differential side bearings.
NOTE: Align the match marks.
NOTE: The bolt threads must be clean.
27. Install the differential bearing caps.
    1. Position the bearing cap onto the leg.
    2. Apply threadlock to the bolt threads, and install the bolts.
       • Tighten the bolts enough to eliminate visible space between the bearing cap and leg. Do not tighten the bolts to the appropriate torque at this time.
Fig 25: Tightening Differential Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
NOTE: Align the differential assembly within the bearing bores before applying preload or damage to the bearings will result.
28. Install the differential bearing adjusting rings.
    • Tighten both adjusting rings until there is zero end play and some backlash between the differential ring gear and pinion. Make sure the adjusting ring tooth aligns so that installation of the adjusting ring cotter pin is possible.
Fig 26: Installing Differential Bearing Adjusting Rings
Courtesy of FORD MOTOR CO.
29. Set the backlash at zero.
    NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.
    • Loosen the adjusting ring on the tooth side of the differential ring gear one tooth and tighten the opposite adjusting ring one tooth. Repeat this process until backlash is at zero.
Fig 27: Checking Differential Ring Gear And Pinion Backlash
Courtesy of FORD MOTOR CO.
30. Set the backlash and the bearing preload to specifications.
    • With a new matched set installed, set the backlash to the specification.
    • With the original matched set installed, set the backlash to the specification recorded prior to disassembly.
    NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.
    • Tighten the adjusting ring on the tooth side of the differential ring gear until backlash is within specifications.
Fig 28: Checking Differential Ring Gear And Pinion Backlash
Courtesy of FORD MOTOR CO.
31. Check the differential ring gear and pinion backlash in 4 equally spaced positions around the differential ring gear.
    • The acceptable backlash tolerance is ± 0.0508 mm (0.002 in) from the backlash specification.
    • If the backlash tolerance varies more than 0.080 mm (0.003 in) between the 4 positions, remove the differential and determine the cause.
Fig 29: Checking Differential Ring Gear And Pinion Backlash
Courtesy of FORD MOTOR CO.
32. Check the differential ring gear and pinion backlash, as described in the previous step, after tightening the bolts.
    • Tighten to 190 Nm (140 lb-ft).
Fig 30: Tightening Bolts
Courtesy of FORD MOTOR CO.
33. Install the adjusting ring cotter pins.
Fig 31: Locating Adjusting Ring Cotter Pins
Courtesy of FORD MOTOR CO.
34. Install the rear anti-lock brake sensor and bolt, if equipped.
    • Tighten to 25 Nm (18 lb-ft).
Fig 32: Installing Rear Anti-Lock Brake Sensor
Courtesy of FORD MOTOR CO.
35. Install the carrier. For additional information, refer to Differential Carrier .