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Home >> Mercury >> 2007 >> Montego Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 48 (Rear Drive Axle/Differential - DANA S110 & S130 -- F450-F550 Super Duty) >> Disassembly And Assembly >> Differential Case and Ring Gear >> Assembly

Differential Case and Ring Gear: Assembly

WARNING: This page is about a different car, the 2005 Ford F550 Super Duty and 2005 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

    All axles 

  1. If removed, install a new anti-lock speed sensor ring with a dead blow hammer.
    Fig 1: Installing Anti-Lock Speed Sensor Ring
    G03918576Courtesy of FORD MOTOR CO.
  2. Press the anti-lock speed sensor ring on the case flange.
    Fig 2: Pressing Anti-Lock Speed Sensor Ring On Case Flange
    G03918576Courtesy of FORD MOTOR CO.

    3. S10 axles 

  3. Install the inner side gear thrust washer and inner side gear.
    Fig 3: Identifying Inner Side Gear And Thrust Washer
    G03918581Courtesy of FORD MOTOR CO.
  4. Align the pinion gear cross shaft with the pin hole vertical position.
    Fig 4: Aligning Pinion Gear Cross Shaft With Pin Hole
    G03918580Courtesy of FORD MOTOR CO.
    5. NOTE: Lightly lubricate all of the mating surfaces with clean axle lubricant. This will aid in assembly and provide initial lubrication.
    Fig 5: Installing First Pinion Gear Thrust Washer And Pinion Gear
    G03918586Courtesy of FORD MOTOR CO.
  5. Install the first pinion gear thrust washer and pinion gear on the pinion cross shaft.
  6. Install the second pinion gear and pinion gear thrust washer on the differential cross shaft.
    Fig 6: Installing Second Pinion Gear And Pinion Gear Thrust Washer
    G03918593Courtesy of FORD MOTOR CO.
  7. Install the differential cross shaft lock pin.
    Fig 7: Installing Differential Cross Shaft Lock Pin
    G03918579Courtesy of FORD MOTOR CO.
    8. NOTE: There is no thrust washer in this location.
    Fig 8: Installing Outer Side Gear
    G03918604Courtesy of FORD MOTOR CO.
  8. Install the outer side gear.
  9. Align the ring gear and the differential case bolt holes. Install the ring gear bolts in the holes finger tight.
    Fig 9: Aligning Ring Gear And Differential Case Bolt Holes
    G03918574Courtesy of FORD MOTOR CO.

    10. S130 axles 

    NOTE: Lubricate both sides of the thrust washer with axle lubricant.
    Fig 10: Identifying Inner Side Gear And Thrust Washer
    G03918581Courtesy of FORD MOTOR CO.
  10. Install the inner side gear thrust washer and inner side gear.
  11. Position the full shaft pinion shaft in the shaft bores of the pinion case. Make sure it is the side that does not have locking pin holes.
    1. Locate the locking pin holes
    2. Position the side pinion and thrust washer.
    3. Start the full shaft into the differential case.
      Fig 11: Positioning Full Shaft Pinion Shaft In Shaft Bores Of Pinion Case
      G03918598Courtesy of FORD MOTOR CO.
  12. Install the opposite side pinion and washer.
    1. Position the thrust washer and pinion.
    2. Push the shaft through the pinion and washer.
      Fig 12: Installing Opposite Side Pinion And Washer
      G03918599Courtesy of FORD MOTOR CO.
  13. Install a side pinion and thrust washer on the halfshaft side.
    Fig 13: Installing Side Pinion And Thrust Washer On Halfshaft Side
    G03918600Courtesy of FORD MOTOR CO.
  14. Install the halfshaft so the pin is facing upward and push the shaft in until it stops.
    Fig 14: Installing Halfshaft
    G03918601Courtesy of FORD MOTOR CO.
  15. Position the halfshaft in the case.
    1. Align the halfshaft in the slot.
    2. Align the locking pin hole with the halfshaft.
      Fig 15: Aligning Halfshaft In Slot
      G03918602Courtesy of FORD MOTOR CO.
  16. Install the locking pin.
    Fig 16: Installing Locking Pin
    G03918603Courtesy of FORD MOTOR CO.
  17. Repeat Steps  6 and  7 to install the opposite half shaft.
    18. NOTE: There is no thrust washer in this location.
    Fig 17: Installing Outer Side Gear
    G03918604Courtesy of FORD MOTOR CO.
  18. Install the outer side gear.
  19. Remove the locating dowels from the ring gear.
    Fig 18: Removing Locating Dowels From Ring Gear
    G03918605Courtesy of FORD MOTOR CO.
  20. Install the dowels over the locking pins.
    Fig 19: Installing Dowels Over Locking Pins
    G03918606Courtesy of FORD MOTOR CO.
  21. Lower the ring gear on the case aligning the locking dowels.
    Fig 20: Aligning Locking Dowels
    G03918607Courtesy of FORD MOTOR CO.
  22. Install the ring gear bolts finger tight.
    Fig 21: Installing Ring Gear Bolts
    G03918574Courtesy of FORD MOTOR CO.

    23. All axles 

  23. Using the special tool and a press, install the differential assembly half on the ring gear half.
    Fig 22: Installing Differential Assembly Half On Ring Gear Half
    G03918609Courtesy of FORD MOTOR CO.
  24. Install the ring gear bolts.
    • Tighten to 203 Nm (150 lb-ft).
      Fig 23: Installing Ring Gear Bolts
      G03918610Courtesy of FORD MOTOR CO.
  25. Using the special tools, install the ring gear side carrier bearing.
    Fig 24: Installing Ring Gear Side Carrier Bearing
    G03918611Courtesy of FORD MOTOR CO.
  26. Using the special tools, install the differential side carrier bearing.
    Fig 25: Installing Differential Side Carrier Bearing
    G03918612Courtesy of FORD MOTOR CO.
  27. Carefully position the differential assembly into the carrier housing.
    28. CAUTION: The bearing cups must seat on the differential side bearings.
    CAUTION: Align the match marks.
    CAUTION: The bolt threads must be clean.
  28. Install the differential bearing caps.
    1. Position the bearing cap onto the leg.
    2. Apply Threadlock 262 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 26: Tightening Differential Bearing Cap Bolts
        G03918613Courtesy of FORD MOTOR CO.
    29. CAUTION: Align the differential assembly within the bearing bores before applying preload or damage to the bearings will result.
  29. 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 27: Installing Differential Bearing Adjusting Rings
      G03918614Courtesy of FORD MOTOR CO.
  30. Set the backlash at zero.
      NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring cotter pin is possible.
      Fig 28: Measuring Differential Ring Gear Backlash
      G03918566Courtesy of FORD MOTOR CO.
    • 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.
  31. 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.
      Fig 29: Measuring Differential Ring Gear Backlash
      G03918566Courtesy of FORD MOTOR CO.
    • Tighten the adjusting ring on the tooth side of the differential ring gear until backlash is within specifications.
  32. 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 inch) from the backlash specification.
    • If the backlash tolerance varies more than 0.080 mm (0.003 inch) between the 4 positions, remove the differential and determine the cause.
      Fig 30: Measuring Differential Ring Gear Backlash
      G03918566Courtesy of FORD MOTOR CO.
  33. 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 31: Tightening Differential Bearing Cap Bolts
      G03918618Courtesy of FORD MOTOR CO.
  34. Install the adjusting ring cotter pins.
    Fig 32: Installing Adjusting Ring Cotter Pins
    G03918568Courtesy of FORD MOTOR CO.
  35. Install the rear anti-lock brake sensor, if equipped.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 33: Installing Rear Anti-Lock Brake Sensor
      G03918620Courtesy of FORD MOTOR CO.
  36. Install the carrier. For additional information, refer to DIFFERENTIAL CARRIER .
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