Differential Case: Installation

ALL AXLES 

CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring.
Fig 1: Positioning Differential Ring Gear, Anti-Lock Speed Sensor Ring And Differential Case
Courtesy of FORD MOTOR CO.
1. Position the differential ring gear, the anti-lock speed sensor ring, 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 new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case.
2. Install the bolts.
   • Apply stud and bearing mount to the bolt threads.
   Fig 2: Installing Differential Ring Gear Bolts

   Courtesy of FORD MOTOR CO.
3. With the pinion depth set and pinion installed, place the differential assembly in the differential housing.
   Fig 3: Placing Differential Assembly In Differential Housing

   Courtesy of FORD MOTOR CO.
4. Install a differential bearing shim on the left side.
   Fig 4: Installing Differential Bearing Shim On Left Side

   Courtesy of FORD MOTOR CO.
CAUTION: Always install the bearing caps in their identical locations and positions.
NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly.
Fig 5: Installing Left Bearing Cap
Courtesy of FORD MOTOR CO.
5. Install the left bearing cap and loosely install the bolts.
6. Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand.
   Fig 6: Installing Right Side Differential Bearing Shims

   Courtesy of FORD MOTOR CO.
7. Install the right side bearing cap and tighten the left side and right side bolts to specification.
   Fig 7: Installing Right Side Bearing Cap

   Courtesy of FORD MOTOR CO.
8. Rotate the differential case to make sure it turns freely.
   Fig 8: Identifying Differential Case

   Courtesy of FORD MOTOR CO.

   MEASURING BACKLASH 

9. Using the special tools, measure and note the differential ring gear backlash.
   • If backlash is within the specification, refer to Backlash within specification in this procedure. The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
   • If a zero backlash condition occurs, refer to Zero backlash in this procedure.
   • If backlash is not within the specification, refer to Backlash not within specification in this procedure.
     Fig 9: Measuring Backlash

     Courtesy of FORD MOTOR CO.
     Fig 10: Backlash/Thickness Change Requirement Table

     Courtesy of FORD MOTOR CO.

   ZERO BACKLASH 

10. 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. Measure the backlash. Refer to Measuring backlash in this procedure.
    Fig 11: Checking Zero Backlash

    Courtesy of FORD MOTOR CO.

    BACKLASH NOT WITHIN SPECIFICATION 

11. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim accordingly.
    • If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.
    Fig 12: Locating Bearing Caps

    Courtesy of FORD MOTOR CO.
12. Rotate the differential assembly several times to verify that the differential bearings seated correctly.
    Fig 13: Rotating Differential Assembly

    Courtesy of FORD MOTOR CO.
13. Using the special tools, recheck the backlash.
    • If backlash is within the specification, refer to Backlash within specification in this procedure. If backlash is not within the specification, repeat Backlash not within specification in this procedure.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 14: Checking Backlash

      Courtesy of FORD MOTOR CO.

    Backlash within specification 

14. Remove the bolts and the bearing caps.
15. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.
    Fig 15: Identifying Left & Right Differential Bearing Shims

    Courtesy of FORD MOTOR CO.
16. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 16: Identifying Special Tool

    Courtesy of FORD MOTOR CO.
17. Install the bearing caps and bolts.
    Fig 17: Installing Bearing Caps And Bolts

    Courtesy of FORD MOTOR CO.
18. Using the special tools, recheck the backlash.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
    Fig 18: Checking Backlash

    Courtesy of FORD MOTOR CO.
19. Install the axle shafts. For additional information, refer to AXLE SHAFT .