Differential Case: Installation

ALL VEHICLES 

CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
Fig 1: Installing Ring Gear
Courtesy of FORD MOTOR CO.
1. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case.
2. Install the bolts.
   • Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts.
     Fig 2: Installing Ring Gear Bolts

     Courtesy of FORD MOTOR CO.
3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing.
   Fig 3: Installing Differential Case In Rear Axle Housing

   Courtesy of FORD MOTOR CO.
4. Install a shim on the left side.
   Fig 4: Installing A 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 Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
5. Install the left bearing cap, and loosely install the bearing cap bolts.
6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
   Fig 6: Installing Larger Shims On Right Side

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

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

   Courtesy of FORD MOTOR CO.

   MEASURE BACKLASH 

9. Using the special tool, measure ring gear backlash.
   • If the backlash is within specification, go to Backlash within specification in this procedure. The specification shown in the illustration is the total allowable range. For the preferred range, refer to the SPECIFICATIONS .
   • If a zero backlash condition occurs, go to Zero backlash in this procedure.
   • If the backlash is not within specification, go to Backlash not within specification in this procedure.
     Fig 9: Measuring Ring Gear Backlash

     Courtesy of FORD MOTOR CO.

   ZERO BACKLASH 

10. If a zero backlash condition occurs, add a 0.50-mm (0.020-inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Go to Measure backlash in this procedure.
    Fig 10: Backlash/Thickness Change Required Table

    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 as shown.
    • If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
    Fig 11: Identifying Adjusting Shims

    Courtesy of FORD MOTOR CO.
12. Install the bearing caps and bearing cap bolts.
    Fig 12: Installing Bearing Caps And Bearing Cap Bolts

    Courtesy of FORD MOTOR CO.
13. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 13: Rotating Differential

    Courtesy of FORD MOTOR CO.
14. Using the special tool, recheck the backlash.
    • If backlash is within specification, go to Backlash within specification in this procedure. If not, go to Measure backlash in this procedure.
    • The specification shown in the illustration is the total allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 14: Rechecking Backlash

      Courtesy of FORD MOTOR CO.

      BACKLASH WITHIN SPECIFICATION 

    • 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 the differential bearing shims are fully seated and the assembly turns freely.
      Fig 15: Seating Differential Bearing Shims

      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.
    • Use the special tool to verify the backlash.
      • The specification shown in the illustration is the total allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 17: Measuring Backlash

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