Differential Case: Installation
WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Install the outboard spacers in the side from which they were removed.
- Place the special tools on the differential case hubs and position the assembly into the differential housing.
- Mount the special tools as shown.
- Force the differential case as far as possible toward the indicator. With force applied, set the indicator at 0. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
- After making sure the reading is repeatable, remove the differential case from the differential housing. Do not remove the special tools from the differential case at this time.
- Start 2 bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and differential case align.
- Press the anti-lock speed sensor on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
- Draw up the 12 new ring gear bolts alternately and evenly.
- Tighten to 298 Nm (220 lb-ft).
- Place the differential assembly with the special tools in the differential housing.
- Install the special tools. Locate the tip of the Clutch Housing Gauge on the flat surface of one of the bolts.
- Force the differential case and ring gear away from the drive pinion. With force applied, set the indicator to 0.
- Force the differential ring gear into mesh with the pinion to obtain an indicator reading. Record this measurement.
- Remove the differential case from the differential housing.
- Remove the special tools from the differential case.
- Place a shim of the thickness determined by the end play between the differential case and the ring gear/pinion on the ring gear side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
- Using the special tool, install the new differential bearing on the differential ring gear side of the differential case.
- Determine the correct shim thickness and place the shim on the differential case hub on the drive pinion side.
- To determine the correct shim thickness, first subtract the thickness of the ring gear side differential case hub shim from the total differential case end play reading recorded earlier. Then, add 0.25 mm (0.010 in) to this amount. This result is the correct thickness of shim to place on the pinion side differential hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
- Using the special tools, install the differential bearing.
- Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
- Using the special tool, drive the differential bearing onto the hub.
- Assemble the differential bearing cups to the differential bearings.
- Using the special tools, spread the differential housing to specifications and position the differential assembly.
- Use a rawhide hammer to seat the differential in the differential housing.
- Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
- Tighten to 108 Nm (80 lb-ft).
- Carry out the Tooth Contact Pattern Check to verify that the final pinion position is correct. For additional information, refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
- Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
- Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
- Place 2 bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover on the differential housing.
- Install the 8 remaining bolts. Tighten the bolts alternately and evenly.
- Tighten to 47 Nm (35 lb-ft).
- If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.
- Fill the axle to specification.
NOTE:
Remove all nicks, burrs and dirt from the differential case hubs to allow the special tools to rotate freely.
NOTE:
The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.
NOTE:
Repeat this and the following step until the same readings appear on the indicator each time. This is the total differential bearing shim thickness necessary, less preload. The final calculation occurs later during assembly.
NOTE:
Apply Threadlock and Sealer to the 2 new bolts.
NOTE:
Apply Threadlock and Sealer to the remaining new bolt threads.
NOTE:
Repeat this and the following step until the same readings appear on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.
CAUTION:
Do not spread the differential housing more than specified.
CAUTION:
Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.
NOTE:
Match the mating letters as noted during disassembly.
NOTE:
Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.