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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1539 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the outboard spacers in the side from which they were removed.
    Fig 1: Identifying Outboard Spacers
    G03883404Courtesy of FORD MOTOR CO.
    2. NOTE: Remove all nicks, burrs and dirt from the differential case hubs to allow the special tools to rotate freely.
    Fig 2: Identifying Special Tools On Differential Case Hubs
    G04643439Courtesy of FORD MOTOR CO.
  2. Place the special tools on the differential case hubs and position the assembly into the differential housing.
    3. NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.
    Fig 3: Identifying Special Tool
    G04643440Courtesy of FORD MOTOR CO.
  3. Mount the special tools as shown.
    4. NOTE: Repeat this and the following step until the same readings appear on the indicator each time. This is the total differential bearing shim thickness necessary, less preload. The final calculation occurs later during assembly.
    Fig 4: Measuring Differential Case End Play
    G04643441Courtesy of FORD MOTOR CO.
  4. Force the differential case as far as possible toward the indicator. With force applied, set the indicator at 0. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
  5. After making sure the reading is repeatable, remove the differential case from the differential housing. Do not remove the special tools from the differential case at this time.
    6. NOTE: Apply Threadlock and Sealer to the 2 new bolts.
    Fig 5: Locating Bolts
    G04643442Courtesy of FORD MOTOR CO.
  6. Start 2 bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and differential case align.
  7. Press the anti-lock speed sensor on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
    Fig 6: Pressing Ring Gear And Anti-Lock Speed Sensor Ring Onto Differential Case
    G03883502Courtesy of FORD MOTOR CO.
    8. NOTE: Apply Threadlock and Sealer to the remaining new bolt threads.
  8. Draw up the 12 new ring gear bolts alternately and evenly.
    • Tighten to 298 Nm (220 lb-ft).
      Fig 7: Identifying Ring Gear
      G03883485Courtesy of FORD MOTOR CO.
  9. Place the differential assembly with the special tools in the differential housing.
    Fig 8: Identifying Special Tool
    G04643445Courtesy of FORD MOTOR CO.
  10. Install the special tools. Locate the tip of the Clutch Housing Gauge on the flat surface of one of the bolts.
    Fig 9: Identifying Special Tool
    G04643446Courtesy of FORD MOTOR CO.
    11. NOTE: Repeat this and the following step until the same readings appear on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.
    Fig 10: Identifying Special Tool
    G04643447Courtesy of FORD MOTOR CO.
  11. Force the differential case and ring gear away from the drive pinion. With force applied, set the indicator to 0.
  12. Force the differential ring gear into mesh with the pinion to obtain an indicator reading. Record this measurement.
    Fig 11: Identifying Special Tool
    G04643448Courtesy of FORD MOTOR CO.
  13. Remove the differential case from the differential housing.
  14. Remove the special tools from the differential case.
  15. Place a shim of the thickness determined by the end play between the differential case and the ring gear/pinion on the ring gear side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
  16. Using the special tool, install the new differential bearing on the differential ring gear side of the differential case.
    Fig 12: Identifying Special Tool For Differential Bearing Installation
    G03883526Courtesy of FORD MOTOR CO.
  17. Determine the correct shim thickness and place the shim on the differential case hub on the drive pinion side.
    • To determine the correct shim thickness, first subtract the thickness of the ring gear side differential case hub shim from the total differential case end play reading recorded earlier. Then, add 0.25 mm (0.010 in) to this amount. This result is the correct thickness of shim to place on the pinion side differential hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
  18. Using the special tools, install the differential bearing.
    1. Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
    2. Using the special tool, drive the differential bearing onto the hub.
      Fig 13: Identifying Special Tool
      G04643450Courtesy of FORD MOTOR CO.
  19. Assemble the differential bearing cups to the differential bearings.
    20. CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.
  20. Using the special tools, spread the differential housing to specifications and position the differential assembly.
    • Use a rawhide hammer to seat the differential in the differential housing.
      Fig 14: Using Special Tool To Spread Differential Housing
      G03918287Courtesy of FORD MOTOR CO.
    21. NOTE: Match the mating letters as noted during disassembly.
  21. Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
    • Tighten to 108 Nm (80 lb-ft).
      Fig 15: Locating Differential Bearing Caps
      G04414224Courtesy of FORD MOTOR CO.
  22. Carry out the Tooth Contact Pattern Check to verify that the final pinion position is correct. For additional information, refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
  23. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
    24. NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.
    Fig 16: Proper Application Of Sealant To Differential Housing Cover
    G03878622Courtesy of FORD MOTOR CO.
  24. Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
  25. Place 2 bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover on the differential housing.
  26. Install the 8 remaining bolts. Tighten the bolts alternately and evenly.
    • Tighten to 47 Nm (35 lb-ft).
    • If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.
  27. Fill the axle to specification.
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