Differential Case and Ring Gear: Assembly

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

Lubricate the differential side gear thrust washer and the differential side gear journals with axle lube, then position the differential side gear thrust washers on the differential side gears.

Fig 1: Positioning Differential Side Gear Thrust Washers

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Install the differential side gears.

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

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Using axle lubricant, lubricate the differential pinion gear thrust washers and the differential pinion gears.

Fig 3: Lubricating Differential Pinion Gear Thrust Washers

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Install the differential pinion gears and differential pinion gear thrust washers 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 pinion shaft.

Fig 6: Identifying Differential Pinion Shaft

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NOTE: If a new pinion shaft lock bolt is unavailable, coat the original bolt threads with threadlock and sealer prior to installation.

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

Fig 7: Identifying Differential Pinion Shaft Lock Bolt

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Using the Differential Side Bearing Installer, install new differential bearings.

Fig 8: Identifying Special Tools (205-009)

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Press the differential ring gear on the differential assembly.

Fig 9: Pressing Differential Ring Gear On Differential Case

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Apply stud and bearing mount to the 10 new differential ring gear bolt threads and install the new differential ring gear bolts.
- Tighten to 105 Nm (77 lb-ft).

Fig 10: Identifying Differential Ring Gear Bolts

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