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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 451 (Rear Drive Axle/Differential - Ford 8.8" Ring Gear) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

    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: Identifying Anti-Lock Speed Sensor Ring
    G03272530Courtesy 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 Ring Gear Bolts
      G03272531Courtesy 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
    G03272532Courtesy of FORD MOTOR CO.
  4. Install a differential bearing shim on the left side.
    Fig 4: Installing Differential Bearing Shim On Left Side
    G03272533Courtesy of FORD MOTOR CO.
    5. 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
    G03272534Courtesy 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 Progressively Larger Differential Bearing Shims On Right Side
    G03272535Courtesy 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
    G03272536Courtesy of FORD MOTOR CO.
  8. Rotate the differential case to make sure it turns freely.
    Fig 8: Rotating Differential
    G03272537Courtesy of FORD MOTOR CO.

    9. 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.
      BACKLASH SPECIFICATION CHART

      Backlash Change Required Thickness Change Required
      mm Inch mm Inch
      0.025 0.001 0.050 0.002
      0.050 0.002 0.050 0.002
      0.076 0.003 0.101 0.004
      0.101 0.004 0.152 0.006
      0.127 0.005 0.152 0.006
      0.152 0.006 0.203 0.008
      0.177 0.007 0.254 0.010
      0.203 0.008 0.254 0.010
      0.228 0.009 0.304 0.012
      0.254 0.010 0.355 0.014
      0.279 0.011 0.355 0.014
      0.304 0.012 0.406 0.016
      0.330 0.013 0.457 0.018
      0.335 0.014 0.457 0.018
      0.381 0.015 0.508 0.020
      Fig 9: Measuring Differential Ring Gear Backlash
      G03272538Courtesy of FORD MOTOR CO.

    10. 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 10: Identifying Bearing Cap
    G03272539Courtesy of FORD MOTOR CO.

    11. 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 11: Identifying Bearing Cap
      G03272540Courtesy of FORD MOTOR CO.
  12. Rotate the differential assembly several times to verify that the differential bearings seated correctly.
    Fig 12: Rotating Differential Assembly
    G03272541Courtesy 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 13: Checking Backlash
      G03272542Courtesy of FORD MOTOR CO.

    14. 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 14: Removing Bolts And Bearing Caps
    G03272543Courtesy of FORD MOTOR CO.
  16. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 15: Seating Differential Bearing Shims
    G03272544Courtesy of FORD MOTOR CO.
  17. Install the bearing caps and bolts.
    Fig 16: Installing Bearing Caps And Bolts
    G03272545Courtesy 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 17: Checking Backlash
      G03272546Courtesy of FORD MOTOR CO.
  19. Install the axle shafts. For additional information, refer to AXLE SHAFT .
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