Differential Carrier: Assembly

WARNING: This page is about a different car, the 2020 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.

Lubricate the differential steel clutch plates. Soak the differential friction plates for no less than 15 minutes.
Material: Motorcraft® Additive Friction Modifier / XL-3 (EST-M2C118-A)

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NOTE: Do not mix the clutch plates, clutch discs or shim from one side with the other.

Assemble the differential clutch packs on their respective differential side gear.

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Place the base portion of the Differential Clutch Gauge in a vise. Install the differential side gear and differential clutch pack (without the shim and spacer) on the tool. Use Special Service Tool: 205-135 Gauge, Differential Clutch. Use the General Equipment: Vise

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Position the Differential Clutch Gauge hand-tight on top of the differential clutch pack. Use Special Service Tool: 205-135 Gauge, Differential Clutch. Use the General Equipment: Vise

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Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. Use the differential clutch pack chart to determine the correct thickness clutch shim to use. Refer to: Specifications . Use Special Service Tool: 205-135 Gauge, Differential Clutch. Use the General Equipment: Vise Use the General Equipment: Feeler Gauge
Torque: 59 lb.in (6.7 Nm)

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NOTE: Do not use more than 2 shims per side.

With the special tool removed, Install the selective shim on the differential side gear and clutch pack assembly.

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Lube and install the differential side gear assemblies in the differential case.
Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL (WSS-M2C942-A)

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Lube and install the differential pinion gear and differential pinion thrust washer assemblies in the differential case.
Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL (WSS-M2C942-A)

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NOTE: The s-spring has tension and may need to be tapped in with a soft faced mallet.

Install the differential S-spring. Use the General Equipment: Rubber Mallet

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NOTE: The pinion shaft may require to be tapped in with a soft-faced hammer.
1. Install the differential pinion shaft. Use the General Equipment: Rubber Mallet
2. Install the new differential pinion shaft bolt.
  Torque: 25 lb.ft (34 Nm)
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Apply a 1/8-inch bead of maximum strength retaining compound on the rear face of the ring gear in the pattern shown.
Material: Retaining Compound / Loctite® 638™ (WSK-M2G349-A8)

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NOTE: Make sure new components is installed.

NOTE: Only tighten the bolt finger tight at this stage.

Position the ring gear onto the differential carrier. Align the ring gear using 3 new bolts. Using the general equipment: press the ring gear into place. Use the General Equipment: Hydraulic Press

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NOTE: Install all the bolts finger tight before final tightening.

NOTE: Tighten the ring gear bolts in a cross pattern.

Install the ring gear and the new ring gear bolts.

Torque: 100 lb.ft (135 Nm)

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Using the special tools, install the new differential bearings. Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 205-1016 Installer, Differential Bearing.

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NOTE: The initial minimum break-away torque, if original clutch plates are used, must be within the specification below. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary.

Using the special tool, check the torque required to rotate one differential side gear. Use Special Service Tool: 205-384 (T97T-4205-A) Gauge, Differential (Traction Lock). Use the General Equipment: Vise

Torque: 20 lb.ft (27 Nm)

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Install the differential carrier. Refer to: Differential Carrier .