Disassembly And Assembly Of Subassemblies: Differential: Assembly

1. Clean the components with a suitable solvent and use compressed air to dry all parts. Perform the following before assembly:
   • Check for damaged or worn gears and washers.
   • Inspect the speedometer drive gear for damage or wear.
2. Install the speedometer drive gear.
Fig 1: Installing Speedometer Drive Gear
Courtesy of FORD MOTOR CO.
3. Use (A) Driver Handle or a press, along with (B) Bearing Cone Replacer to install a new (C) differential bearing (speedometer drive gear end).
Fig 2: Installing Differential Bearing
Courtesy of FORD MOTOR CO.
4. Use (A) Driver Handle or a press, along with (B) Bearing Cone Replacer to install a new (C) differential bearing (ring gear end).
Fig 3: Installing Differential Bearing
Courtesy of FORD MOTOR CO.
5. Install the differential side gear thrust washers, differential pinion thrust washers, differential pinion gears, and the differential side gears.
   • Rotate the gears to align the differential gears with the pinion shaft hole.
Fig 4: Installing Differential Side Gear Thrust Washers, Differential Pinion Thrust Washers, Differential Pinion Gears & Differential Side Gears
Courtesy of FORD MOTOR CO.
6. Install the differential pinion shaft.
Fig 5: Installing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
7. Install the differential pinion shaft lock pin. Stake the differential pinion shaft lock pin to prevent it from coming out of the differential case.

Fig 6: Installing Differential Pinion Shaft Lock Pin

Courtesy of FORD MOTOR CO.