Differential Carrier: Installation

WARNING: This page is about a different car, the 2018 Lincoln Navigator. However, it is still accessible from the selected car via links, so may be relevant.

lubricate and install the differential carrier side shims.

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Install the differential carrier.
- Position the differential bearing cups on the differential bearings.
- Lower the differential carrier assembly in place between the differential bearing shims.
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NOTE: The fixture mounting bolts must have the minimum of 12.7 mm (0.500 In) of thread engagement in the carrier or damage to the component may occur.

NOTE: Always install the differential bearing caps in their original positions or damage to the component may occur.

NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.
- With the differential housing spread to 0.762 mm (0.030 in) maximum. Install the differential caps and the differential cap bolts.
- Finger tighten the differential bearing cap bolts prior to releasing the carrier spreader. Use Special Service Tool: 205-001 (TOOL-4000-E) Spreader, Differential Carrier., 205-335 (T93P-4000-A) Spreader, Differential Housing (Plate)., 205-368 (T96T-4000-A) Adapter for Differential Housing Spreader.
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1. Loosen and Remove the special tools. Use Special Service Tool: 205-001 (TOOL-4000-E) Spreader, Differential Carrier., 205-335 (T93P-4000-A) Spreader, Differential Housing (Plate)., 205-368 (T96T-4000-A) Adapter for Differential Housing Spreader.
2. Tighten the differential bearing cap bolts.
  Torque: 77 lb.ft (105 Nm)
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Using the dial indicator, measure the differential ring gear backlash at 4 equally spaced points. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

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NOTE: The fixture mounting bolts must have the minimum of 12.7 mm (0.500 In) of thread engagement in the carrier or damage to the component may occur.

Remove the axle assembly from the special tool. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.

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NOTE: Make sure that the mating surface and the bore is free of corrosion and foreign material, avoid particles getting into the bore. Particles might stick on the vent valve assembly and cause damage to vent valve.

Clean the mating surface of the axle and the axle tube.

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Apply a new continuous bead of sealant to the differential housing as shown in the figure.
Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

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Install the axle tube and the axle tube bolts.
Torque: 54 lb.ft (73 Nm)

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Install the new inner and outer circlips.

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NOTE: The axle shaft is not fully seated until the circlip is engaged with the differential side gear.

Install the axle shaft.

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NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying the new silicone gasket.

Clean the gasket mating surface of the axle and the differential housing cover.

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NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has correctly cured.

Apply a new continuous bead of sealant to the differential housing cover as shown in the figure.

Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

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Install the differential cover and differential cover bolts.
Torque: 24 lb.ft (32 Nm)

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Install the front axle assembly. Refer to: Axle Assembly .