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Differential Carrier: Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the special tools.
    • Position the clutch housing gauge needle in the differential carrier spreader adapter hole.
      Fig 1: Positioning Clutch Housing Gauge Needle In Differential Carrier Spreader Adapter Hole
      G03912998Courtesy of FORD MOTOR CO.
    2. CAUTION: Overspreading can damage the differential housing.
    Fig 2: Spreading Differential Housing
    G03912921Courtesy of FORD MOTOR CO.
  2. Spread the differential housing to the specification.
  3. Remove the special tools.
    Fig 3: Identifying Special Tools
    G03913000Courtesy of FORD MOTOR CO.
    4. NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the differential housing.
  4. Install the differential bearing cups and the differential assembly in the differential housing.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential assembly in place.
      Fig 4: Installing Differential Bearing Cups And Differential Assembly In Differential Housing
      G03912923Courtesy of FORD MOTOR CO.
    5. CAUTION: Do not tighten the differential bearing cap bolts to specification at this time.
  5. Install the differential bearing caps in their original positions.
    1. Position the differential bearing caps.
    2. Install the differential bearing cap bolts hand-tight.
      Fig 5: Identifying Differential Bearing Caps
      G03912924Courtesy of FORD MOTOR CO.
  6. Remove the special tools.
  7. Tighten the differential bearing cap bolts.
    • Tighten to 61 Nm (45 lb-ft).
      Fig 6: Locating Differential Bearing Cap Bolts
      G03912925Courtesy of FORD MOTOR CO.
  8. Verify that the differential assembly rotates freely.
  9. Check the ring gear backlash and remove the special tools.
    Fig 7: Measuring Differential Ring Gear Backlash
    G03912927Courtesy of FORD MOTOR CO.
  10. Install the RH axle shaft.
    11. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.
    CAUTION: Install the differential housing cover within 15 minutes of applying the silicone material.
    CAUTION: Allow the sealant to cure for one hour before filling the axle with lubricant.
    Fig 8: Applying Sealant To Differential Housing Cover Mounting Surface
    G03912929Courtesy of FORD MOTOR CO.
  11. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
  12. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 29 Nm (21 lb-ft).
  13. Install the axle assembly. For additional information, refer to AXLE ASSEMBLY .
  14. Fill the axle with rear axle lubricant to 9.56 mm (0.38 in) below the bottom of the filler hole.
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