Disassembly And Assembly Of Subassemblies: Differential: Assembly

WARNING: This page is about a different car, the 2002 Mercury Villager. However, it is still accessible from the selected car via links, so may be relevant.

Position the side gear thrust washers on the back of the differential side gears.

Fig 1: Positioning Side Gear Thrust Washers On Back Of Differential Side Gears
Courtesy of FORD MOTOR CO.
Position the pinion gear thrust washers on the back of the pinion gears.

Fig 2: Positioning Pinion Gear Thrust Washers On Back Of Pinion Gears
Courtesy of FORD MOTOR CO.
Install the side gear/thrust washers into the differential case.

Fig 3: Installing Side Gear/Thrust Washers Into Differential Case
Courtesy of FORD MOTOR CO.
Install the pinion gears in the differential case.
- Rotate the pinion gears to properly position.
  
  Fig 4: Installing Pinion Gears In Differential Case
  Courtesy of FORD MOTOR CO.
Install the differential pinion shaft.

Fig 5: Installing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Install the shaft lock pin into the differential case.

Fig 6: Installing Shaft Lock Pin Into Differential Case
Courtesy of FORD MOTOR CO.
Install the speedometer gear.

Fig 7: Installing Speedometer Gear
Courtesy of FORD MOTOR CO.
Install the differential bearing.

Fig 8: Installing Differential Bearing (1 Of 2)
Courtesy of FORD MOTOR CO.
Install the differential bearing.

Fig 9: Installing Differential Bearing (2 Of 2)
Courtesy of FORD MOTOR CO.

CAUTION: Install the final drive gear in the original position based upon the marks made during disassembly.

If removed, install the differential final drive gear.
1. Position the gear.
2. Install the bolts.
  
  Fig 10: Installing Bolts
  Courtesy of FORD MOTOR CO.