Differential Case Assembly

For limited slip & locking differential assemblies, refer to ``Ford Drive Axle w/Integral Carrier'' section for assembly procedures. For adjustment procedures on these differentials, refer to step 9 in this procedure.
1. Install differential case in a vise, then apply suitable lubricant to side gear thrust washers and to hubs and thrust face of the new side gears.
2. Assemble both side gears and apply suitable lubricant to the spherical washers and pinion mate gears, then assemble pinion mate gears and washers.
3. Install both side gears and thrust washers, then the pinion mate gears and washers to hold side gears in position.
4. Rotate side gears until holes of washers and pinion gears line up with holes of the case. If gears cannot be rotated by hand, install one of the axle shafts into the side gear spline and use a pipe wrench to turn shaft.
5. Line up gear holes with those of the differential case using a suitable drift, then install pinion mate shaft. Ensure lock pin hole of shaft is lined up with lock pin hole of case.
6. Install lock pin, then peen metal of case over pin to lock in position. The semi-float shaft riding bearing design uses a locking pin that is installed using a suitable wrench. Use a new lock pin and assemble finger tight. This prevents differential side gears and differential pinion mate gears from rotating in the case and dropping out when servicing the carrier section. A new lock pin should be installed after assembling the axle shafts.
7. Install ring gear to case, then the ring gear attaching screws. Torque ring gear attaching screws alternately to approximately 115 ft. lbs. on except model 30 axle or 45---60 ft. lbs on model 30 axle.
8. Install differential bearings onto case using suitable tool.
9. Install differential case assembly into carrier, less pinion, then mount suitable dial indicator on face of housing.
10. Locate tip of indicator on flat surface of one of the ring gear screw spot faces, then force differential assembly as far as possible in the direction towards the indicator. With force still applied, set indicator at zero.
11. Force differential assembly as far as it will go in the opposite direction. Repeat this step until the same reading is obtained, then record this reading. This reading will be the total amount of shims required, less preload, and will be calculated later during assembly.
12. Remove indicator and differential assembly from housing. Do not remove bearings from differential case at this time.