Differential Case & Ring Gear - Conventional: Assembly

WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate the differential side gear thrust washers and the differential side gear journals with rear axle lubricant.
Position the differential side gear thrust washers on the differential side gears.

Fig 1: Positioning Differential Side Gear Thrust Washers

Courtesy of FORD MOTOR CO.

Position the differential side gear and thrust washer assemblies in the differential case.

Fig 2: Identifying Differential Side Gears & Differential Side Gear Thrust Washers

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Lubricate the differential pinion thrust washers and differential pinion gears with rear axle lubricant and assemble.

Fig 3: Lubricating Differential Pinion Gear Thrust Washers

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Engage the differential pinion gears opposite the differential side gears.

Fig 4: Identifying Differential Pinion Gears & Differential Pinion Gear Thrust Washers

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Rotate the differential pinion gears to align with the differential pinion shaft bore.

Fig 5: Rotating Differential Pinion Gears

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Insert the differential pinion shaft.
- Align the bolt hole in the differential pinion shaft with the bolt hole in the differential case.

Fig 6: Identifying Differential Pinion Shaft

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Install a new differential pinion shaft bolt finger-tight.

Fig 7: Identifying Differential Pinion Shaft Lock Bolt

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If necessary, using the special tool, install the new differential bearings.

Fig 8: Installing Differential Bearings On Differential Case

Courtesy of FORD MOTOR CO.

Position the differential ring gear and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.

Fig 9: Pressing Differential Ring Gear On Differential Case

Courtesy of FORD MOTOR CO.

NOTE: Apply stud and bearing mount to the bolt threads.

Install the 10 differential ring gear bolts.
- Tighten to 114 Nm (84 lb-ft).

Fig 10: Identifying Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

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

WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article. Failure to follow these instructions may result in serious personal injury.

If equipped with fire suppression system, repower the system.