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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 580 (Rear Drive Axle/Differential-Ford 9.75" Ring Gear) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    ALL VEHICLES 

    CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
    Fig 1: Installing New Anti-Lock Speed Sensor On Differential Case
    G02761132Courtesy 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 sealer to the ring gear bolts.
    Fig 2: Installing Ring Gear Bolts
    G02761133Courtesy of FORD MOTOR CO.
  3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing.
    Fig 3: Placing Differential Case In Rear Axle Housing
    G02761134Courtesy of FORD MOTOR CO.
  4. Install a shim on the left side, of the specification shown.
    Fig 4: Installing A Shim On Left Side
    G02761135Courtesy of FORD MOTOR CO.
    5. CAUTION: The bearing caps must be installed in their original 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 Bolts
    G02761136Courtesy 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 inserted by hand.
    Fig 6: Installing Progressively Larger Shims On Right Side
    G02761137Courtesy of FORD MOTOR CO.
  7. Install the right side bearing cap and tighten the bolts.
    Fig 7: Tightening Right Side Bearing Cap Bolts
    G02761138Courtesy of FORD MOTOR CO.
  8. Rotate the differential case to make sure it rotates freely.
    Fig 8: Checking Differential Case Rotates Freely
    G02761139Courtesy 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 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
    G02761140Courtesy 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. Go to Measure Backlash in this procedure.
    Fig 10: Backlash Shim Specifications Table
    G02761141Courtesy 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: Installing A Thicker Shim And A Thinner Shim
    G02761142Courtesy of FORD MOTOR CO.
  12. Install the bearing caps and bearing cap bolts.
    Fig 12: Installing Bearing Caps And Bearing Cap Bolts
    G02761143Courtesy of FORD MOTOR CO.
  13. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 13: Checking Differential Bearings Are Correctly Seated
    G02761144Courtesy 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: Measuring Backlash
    G02761145Courtesy of FORD MOTOR CO.

    BACKLASH WITHIN SPECIFICATION 

  15. 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: Installing Bearing Caps And Bolts
    G02761146Courtesy of FORD MOTOR CO.
  16. Install the bearing caps and bearing cap bolts.
    Fig 16: Installing Bearing Caps And Bearing Cap Bolts
    G02761147Courtesy of FORD MOTOR CO.
  17. 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
    G02761148Courtesy of FORD MOTOR CO.
  18. Install the axle shafts. For additional information, refer to AXLE SHAFT .
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