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Home >> Ford >> 2002 >> Crown Victoria Base, 4.6 9 >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear >> Disassembly & Assembly >> Differential Case & Ring Gear - Conventional >> Assembly

Differential Case & Ring Gear - Conventional: Assembly

  1. Lubricate the differential side gear thrust washers and the differential side gear journals.
    • Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL meeting Ford specification WSP-M2C197-A.
  2. Position the differential side gear thrust washers on the differential side gears.
    Fig 1: Identifying Differential Side Gears & Side Gear Thrust Washers
    G01941005Courtesy of FORD MOTOR CO.
  3. Position the differential side gear and thrust washer assemblies in the differential case (4204).
    Fig 2: Positioning Differential Side Gear & Thrust Washer Assemblies In Differential Case
    G01941006Courtesy of FORD MOTOR CO.
  4. Lubricate and assemble the differential pinion thrust washers and differential pinion gears.
    • Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL meeting Ford specification WSP-M2C197-A.
    Fig 3: Identifying Differential Pinion Thrust Washer & Differential Pinion Gear
    G01941007Courtesy of FORD MOTOR CO.
  5. Engage the differential pinion gears opposite the differential side gears.
    Fig 4: Engaging Differential Pinion Gears Opposite Differential Side Gears
    G01941008Courtesy of FORD MOTOR CO.
  6. Rotate the differential pinion gears to align with the differential pinion shaft bore.
    Fig 5: Rotating Differential Pinion Gears To Align With Differential Pinion Shaft Bore
    G01941009Courtesy of FORD MOTOR CO.
  7. Insert the differential pinion shaft.
    • Align the bolt hole in the differential pinion shaft with the bolt hole in the differential case.
    Fig 6: Identifying Differential Pinion Shaft
    G01941010Courtesy of FORD MOTOR CO.
    8. NOTE: If a new bolt is unavailable, coat the threads with Threadlock® and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation.
    Fig 7: Identifying Differential Pinion Shaft Bolt
    G01941011Courtesy of FORD MOTOR CO.
  8. Install a new bolt finger-tight.
  9. Using the special tool, install the new differential bearings.
    Fig 8: Installing Differential
    G01941012Courtesy of FORD MOTOR CO.
  10. Position the differential ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.
    Fig 9: Installing Ring Gear
    G01941013Courtesy of FORD MOTOR CO.
  11. Install the bolts.
    • Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to bolt threads.
    Fig 10: Tightening Ring Gear Bolts
    G01941014Courtesy of FORD MOTOR CO.
  12. Install the differential assembly. For additional information, refer to DIFFERENTIAL CASE .
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