Differential Case and Ring Gear - One-Piece, Traction-Lok®: Assembly

WARNING: This page is about a different car, the 2009 Ford Pickup and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Pre-lubricate each steel clutch plate and soak all friction plates in friction modifier.

Fig 1: Identifying Friction Plates & Friction Modifier

Courtesy of FORD MOTOR CO.

NOTE: Do not mix the differential clutch packs or shims from one side with the other.

NOTE: The Belleville spring is a dished plate.

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

Fig 2: Exploded View Of Differential Side Gears, Clutch Plates & Clutch Discs

Courtesy of FORD MOTOR CO.

Clamp the bolt head of the Differential Gauge in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.

Fig 3: Differential Clutch Pack & Differential Side Gear On Special Tool (205-380)

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Position the Differential Clutch Gauge on top of the differential clutch pack.

Fig 4: Identifying Special Tool (205-135) On Top Of Differential Clutch Pack

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Install the Differential Clutch Gauge over the disc and differential clutch pack.

Fig 5: Identifying Special Tool (205-135) Over Disc & Differential Clutch Pack

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Install the nut of the gauge over the top and base stud.
- Tighten to 6.7 Nm (60 lb-in).

Fig 6: Nut Of Gauge Over Top & Base Stud

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Use a feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. Select the correct shim size.

Part Number	Description
F75Z-4A324-DA	0.030 in
F75Z-4A324-EA	0.035 in
F75Z-4A324-FA	0.040 in
F75Z-4A324-GA	0.045 in
F75Z-4A324-HA	0.050 in
F75Z-4A324-JA	0.055 in
F75Z-4A324-KA	0.060 in

Fig 7: Checking Clutch Pack Clearance

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Place the shim and Belleville spring on the differential clutch pack.
- The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case.

Fig 8: Cutaway View Of Shim, Spring, Clutch Pack & Differential Side Gear

Courtesy of FORD MOTOR CO.

Insert the differential clutch packs, the selected shims, Belleville springs and differential side gears into the differential case.
- Hold the upper differential clutch pack and side gear assembly in place to prevent it from falling out of the differential case.

Fig 9: Installing Assembly In Case

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 Limited Slip Differential Rotator in the differential case.
1. Position the Step Plate in the bottom side gear bore.
2. Position the nut in the top side gear bore and hold it in place.
3. Install the hex-head screw and tighten it 2 turns after it contacts the bottom Step Plate.

Fig 10: Assembling Limited Slip Differential Rotator In Differential Case

Courtesy of FORD MOTOR CO.

NOTE: Pre-lubricate both sides of the differential pinion thrust washers with clean rear 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 thrust washers in the window of the differential case so they mesh with the differential side gear teeth.

Fig 11: Differential Pinion Gears & Differential Pinion Thrust Washers In Window Of Differential Case

Courtesy of FORD MOTOR CO.

NOTE: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool.

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.

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 mating shaft holes are lined up exactly with the holes in the differential pinion gears.

Fig 12: Inserting Special Tool (205-246) Into Pinion Shaft Bore

Courtesy of FORD MOTOR CO.

Install the differential pinion shaft in the differential case.

Fig 13: Identifying Differential Pinion Shaft

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Install a new differential pinion shaft lock bolt.
- Tighten to 30 Nm (22 lb-ft).

Fig 14: Identifying Differential Pinion Shaft Lock Bolt

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Check the rotational torque required to rotate one differential side gear.
- Install the Differential Clutch Preload Gauge with the (1/2-inch drive hole) as shown.
- The initial break-away torque, if original clutch plates are used, must be within specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.

Fig 15: Checking Rotational Torque (With Specifications)

Courtesy of FORD MOTOR CO.

Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the 12 new ring gear bolts.
- Tighten to 150 Nm (111 lb-ft).

Fig 16: Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Install the differential carrier. For additional information, refer to Differential Carrier .