Disassembly And Assembly Of Subassemblies: Differential: Assembly

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Install the speedometer drive gear.

CAUTION: Press the differential bearings onto the differential case by the inner race only. Pressing on the outer race will damage the bearing.

Using the special tool, press the differential bearing onto the differential case.
- Always install new bearings and cups as a set.
  
  Fig 1: Locating Special Tool, Differential Bearing And Differential Case
  Courtesy of FORD MOTOR CO.
Rotate the differential case. Using the special tool, press on the differential bearing.
- Always install new bearings and cups as a set.
  
  Fig 2: Locating Special Tool And Differential Bearing
  Courtesy of FORD MOTOR CO.
Install the differential side gears and thrust washers.
Install the differential pinion gears and thrust washers.
Install the differential pinion shaft.
Install the new differential pinion shaft lock pin.

Fig 3: Locating Differential Pinion Shaft Lock Pin
Courtesy of FORD MOTOR CO.