Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Differential Carrier: Assembly
- 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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NOTE: Do not use more than 2 shims per side.
Install two shims with a total thickness of 0.110 in (2.8 mm) on both differential side gear and clutch pack assemblies.
- 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)
- 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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- Install the differential pinion shaft.
- Install the new differential pinion shaft bolt.
Torque: 25 lb.ft (34 Nm)
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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)
- 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: 205-022 (T66L-4204-A) Gauge, Differential Clutch. Use the General Equipment: Vise
Torque: 20 lb.ft (27 Nm)
- Install the differential carrier. Refer to: Differential Carrier .
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.