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Differential Case: Assembly

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Place the differential case into a vise with soft jaws.
  2. Lubricate all components with axle lubricant.
    • The differential side gear thrust washers.
    • The differential side gear hubs and thrust faces.
    • The differential pinion thrust washers.
    • The differential pinion gears.
      • Assemble the gears and their respective washers.
  3. Lubricate the gears with axle lubricant, then install them into the differential case.
    • Install and hold the differential side gears and thrust washers in the differential case. Then, install the differential pinion gears and thrust washers and rotate them until the pinion shaft bore in the case and gears align.
      • If hand rotation of the gears is not possible, install an axle shaft into the differential side gear and turn the shaft with a pipe wrench.
      • If necessary, use a drift to align the pinion shaft bores.
        Fig 1: Identifying Differential Side Gears
        G03883859
  4. Install the differential pinion shaft, aligning the lockpin bore in the differential case and the pinion shaft.
    Fig 2: Installing Differential Pinion Shaft
    G04644465
  5. Install the differential pinion shaft lockpin.
    • Peen the differential case metal over the lockpin, in 2 places, 90 degrees from the slot in the lockpin.
      Fig 3: Installing Differential Pinion Shaft Lock Pin
      G04644466
  6. Install the outboard spacers in the side from which they were removed.
    Fig 4: Identifying Outboard Spacers
    G03883404
    7. 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.
    NOTE: Remove all nicks, burrs and dirt from the differential case hubs, to allow the special tools to rotate freely.
  7. Place the special tools on the differential case hubs and position the assembly into the differential housing.
    • Position the remaining special tool.
      Fig 5: Placing Special Tools On Differential Case Hubs
      G04644468
    8. 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 6: Identifying Special Tool
    G04644469
  8. 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.
  9. 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.
    10. NOTE: Apply Threadlock and Sealer to the 12 new bolts.
    Fig 7: Locating Threadlock And Sealer Apply To Bolts
    G04644470
  10. Start 2 bolts through the differential case flange and into the differential ring gear to make sure the differential ring gear and the differential case align.
  11. Install the remaining 10 ring gear bolts and draw up the new ring gear bolts alternately and evenly.
    • Tighten to 183 Nm (135 lb-ft).
      Fig 8: Identifying Ring Gear
      G03883485
  12. Position the differential case with the special tool into the differential housing.
    Fig 9: Positioning Differential Case With Special Tool
    G04644472
    13. NOTE: Repeat this step until there is a consistent reading.
  13. Using the special tools, determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.
    • Force the ring gear away from the pinion and zero the special tool.
    • Force the ring gear into mesh with the pinion.
      • Rock the ring gear to allow the teeth of the gears to mesh.
    • Record the reading.
      Fig 10: Measuring Thickness Of Differential Bearing Shims
      G04644473
  14. Remove the differential case with the special tool from the differential housing.
    Fig 11: Removing Differential Case With Special Tool
    G04644474
  15. Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case. Differential bearing shims are available in the thickness shown in the following chart.
    • For example, a reading of 1.14 mm (0.045 in), requires that 1.14 mm (0.045 in) shims be placed on the ring gear side of the differential case.
    AVAILABLE DIFFERENTIAL BEARING SHIMS

    mm Inch
    0.076 0.003
    0.127 0.005
    0.254 0.010
    0.762 0.030
  16. Using the special tool(s), install the selected differential bearing shim and the differential bearing.
    Fig 12: Installing Differential Bearing Shim And Differential Bearing
    G04644475
  17. Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
    • Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 in) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
  18. Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
  19. Using the special tools, install the selected differential bearing shim and the differential bearing on the drive pinion side of the case.
    1. Place the special tool under the bearing to protect it during the bearing installation.
    2. Using the special tool(s), install the bearing.
      Fig 13: Installing Differential Bearing
      G03883589
  20. Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER - DANA 60 .
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