Differential Case: Assembly

WARNING: This page is about a different car, the 2003 Lincoln Navigator and 2003 Ford Expedition. 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.
Position the differential side gear thrust washers on the differential side gears.

Fig 1: Positioning Differential Side Gear Thrust Washers On Differential Side Gears
Courtesy of FORD MOTOR CO.
Position the differential side gears.

Fig 2: Positioning Differential Side Gears
Courtesy of FORD MOTOR CO.
Lubricate the differential pinion thrust washers and the differential pinion gears and assemble them.

Fig 3: Lubricating Differential Pinion Thrust Washers And Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Engage the differential pinion gears opposite the differential side gears.

Fig 4: Engaging Differential Pinion Gears Opposite Differential Side Gears
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears to align with the differential pinion shaft bore.

Fig 5: Rotating The Differential Pinion Gears To Align With Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Insert the differential pinion shaft.

Fig 6: Inserting Differential Pinion Shaft
Courtesy of FORD MOTOR CO.

NOTE: If a new pinion shaft bolt is unavailable, coat the threads with sealer.

Fig 7: Installing Differential Pinion Shaft Bolt

Courtesy of FORD MOTOR CO.

Install a new differential pinion shaft bolt.

CAUTION: Do not press on the bearing.

Install the ring gear.
1. Position three bolts to align the holes in the ring gear and the differential case.
2. Using a suitable press, install the ring gear.
  
  Fig 8: Installing Ring Gear
  Courtesy of FORD MOTOR CO.
Install the remaining bolts.

Fig 9: Installing Bolts
Courtesy of FORD MOTOR CO.
Install the differential carrier into the differential carrier housing. For additional information, refer to AXLE ASSEMBLY - FRONT DRIVE .