Differential Case: Installation

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.

Press a new anti-lock speed sensor ring, if removed, and the ring gear on the differential case.
- Align the notch on the differential case flange with the notch on the anti-lock speed sensor ring.
  
  Fig 1: Aligning Notch On Differential Case Flange With Notch On Anti-Lock Speed Sensor Ring
  Courtesy of FORD MOTOR CO.
Install the ring gear bolts.
- Apply stud and bearing mount to the ring gear bolts.
  
  Fig 2: Identifying Tightening Torque Of Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
With pinion depth set and the drive pinion installed, place the differential case in the rear axle housing.

Fig 3: Installing Differential Case In Rear Axle Housing With Pinion Depth
Courtesy of FORD MOTOR CO.
Install a shim on the left side.

Fig 4: Installing Shim On Left Side
Courtesy of FORD MOTOR CO.

CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.

Fig 5: Installing Left Bearing Cap And Loosely Install Bearing Cap Bolts

Courtesy of FORD MOTOR CO.

Install the left bearing cap and loosely install the bearing cap bolts.
Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.

Fig 6: Installing Progressively Larger Shims On Right Side
Courtesy of FORD MOTOR CO.
Install the right side bearing cap and tighten the left side and right side bolts to specification.

Fig 7: Installing Right Side Bearing Cap And Tightening Left Side And Right Side Bolts To Specification
Courtesy of FORD MOTOR CO.
Rotate the differential case to make sure it rotates freely.

Fig 8: Rotating Differential Case To Make Sure It Rotates Freely
Courtesy of FORD MOTOR CO.
Using the special tool, measure the ring gear backlash.
- If the backlash is within specification, go to Step 14.
- If a zero backlash condition occurs, go to Step 10.
- If the backlash is not within specification, go to Step 11.
  
  Fig 9: Measuring Ring Gear Backlash
  Courtesy of FORD MOTOR CO.
  
  Fig 10: Identifying Backlash And Thickness Change Required Table (1 Of 2)
  Courtesy of FORD MOTOR CO.
  
  Fig 11: Identifying Backlash And Thickness Change Required Table (2 Of 2)
  Courtesy of FORD MOTOR CO.
If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Check the backlash. Repeat Step 9.
To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown.
- If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.
  
  Fig 12: Installing Thicker Shim
  Courtesy of FORD MOTOR CO.
Rotate the differential several times to make sure the differential bearings are correctly seated.

Fig 13: Rotating Differential Several
Courtesy of FORD MOTOR CO.
Using the special tool, recheck the backlash.
- If the backlash is within specification, go to Step 14. If the backlash is not within specification, repeat Step 9.
  
  Fig 14: Rechecking Backlash With Special Tool
  Courtesy of FORD MOTOR CO.
Remove the bearing caps and bolts.
- To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
- Using the special tool, make sure that the differential bearing shims are fully seated and the assembly turns freely.
  
  Fig 15: Removing Bearing Caps And Bolts
  Courtesy of FORD MOTOR CO.
Install the bearing caps and bearing cap bolts.

Fig 16: Installing Bearing Caps And Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
Using the special tool, recheck the backlash.
- For further adjustments, Refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
  
  Fig 17: Rechecking Backlash With Special Tool
  Courtesy of FORD MOTOR CO.
Install the axle shafts. Refer to AXLE SHAFT .
Fill the rear axle housing with 2.37 liters (5.5 pints) with the specified lubricant.