Final Drive Carrier and Differential Assembly: Assembly

Clean and inspect the side gears and spider gears and washers for damage or excessive wear and install new components as necessary.

Fig 1: Identifying Side Gears, Spider Gears And Washers
Courtesy of FORD MOTOR CO.
Clean and inspect the differential pin for damage or excessive wear and install new if necessary.

Fig 2: Identifying Differential Pin
Courtesy of FORD MOTOR CO.
Clean and inspect the differential for damage and install new if necessary.
1. Inspect the thrust bearing surfaces.
2. Inspect the differential planetary gear teeth.
3. Inspect the differential planetary gear teeth to be sure they spin freely and do not move back and forth or side to side excessively.
  
  Fig 3: Identifying Differential Thrust Bearing Surface And Differential Planetary Gear Teeth
  Courtesy of FORD MOTOR CO.
Clean and inspect the differential sun gear for damage or excessive wear and install new if necessary.

Fig 4: Identifying Differential Sun Gear
Courtesy of FORD MOTOR CO.

NOTE: Do not mix up the washers from the side or spider gears that they were originally assembled with. Assembly of the differential with the wrong washers can cause excessive wear to the differential carrier, spider or side gears.

Fig 5: Locating Washers On Spider Gears

Courtesy of FORD MOTOR CO.

Install the washers on the side or spider gears that they were removed from.
Position the side gears in the differential carrier.

Fig 6: Positioning Side Gears On Differential Carrier
Courtesy of FORD MOTOR CO.
Place the spider gears in the differential carrier and rotate the side gears with the spider gears until the differential pin hole lines up to the holes in the spider gears.

Fig 7: Rotating Side Gears With Spider Gears
Courtesy of FORD MOTOR CO.
Install the differential pin with the roll pin holes aligned.

Fig 8: Locating Differential Pin And Roll Pin Hole
Courtesy of FORD MOTOR CO.
Using a suitable tool, install a new roll pin.

Fig 9: Installing Roll Pin
Courtesy of FORD MOTOR CO.