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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 385 (Front Drive Axle/Differential - DANA 35) >> Removal & Installation >> Differential Carrier >> Installation

Differential Carrier: Installation

WARNING: This page is about a different car, the 2002 Ford Ranger. 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: Installing Special Tools
    G03434845Courtesy of FORD MOTOR CO.
    2. CAUTION: Overspreading can damage the differential housing.
    Fig 2: Spreading Differential Housing To Specification
    G03434846Courtesy of FORD MOTOR CO.
  2. Spread the differential housing to the specification.
  3. Remove the special tools.
    Fig 3: Removing Special Tools
    G03434847Courtesy of FORD MOTOR CO.
    4. NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the differential housing.
    Fig 4: Installing Differential Bearing Cups & Differential Assembly In Differential Housing
    G03434848Courtesy of FORD MOTOR CO.
  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.
    5. CAUTION: Do not tighten the differential bearing cap bolts to specification at this time.
    Fig 5: Identifying Differential Bearing Caps
    G03434849Courtesy of FORD MOTOR CO.
  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.
  6. Remove the special tools.
  7. Tighten the differential bearing cap bolts.
    • Tighten to 61 Nm (45 lb-ft).
    Fig 6: Tightening Differential Bearing Cap Bolts
    G03434850Courtesy 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: Checking Ring Gear Backlash
    G03434851Courtesy 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 1 hour before filling the axle with lubricant.
    Fig 8: Applying Continuous Bead Of Sealant To Differential Housing Cover Mounting Surface
    G03434852Courtesy 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 - FRONT  .
  14. Fill the axle with 1.54 Liters (3.25 pints) of lubricant.
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