Differential Case and Ring Gear - Conventional: Assembly

WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Position the differential side gear thrust washers on the differential side gears.
- Lubricate the differential side gear thrust washers and the differential side gear journals with axle lubricant.

Fig 1: Identifying Differential Thrust Washers & Differential Side Gears

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Position the differential side gears.

Fig 2: Identifying Differential Side Gears

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Assemble the differential pinion gear thrust washers and the differential pinion gears.
- Lubricate the washers and gears with rear axle lubricant.

Fig 3: Locating Differential Pinion Gears

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Engage the differential pinion gears opposite the differential side gears.

Fig 4: Identifying Differential Pinion Gears Positions

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Rotate the differential pinion gears to align the differential pinion shaft bore.

Fig 5: Aligning Differential Pinion Shaft Bore

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Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.

Fig 6: Identifying Differential Pinion Shaft Lock Bolt

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If removed, use the special tool to install the differential bearings.

Fig 7: Pressing Differential Bearings On Differential Case Using Special Tool

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Press the new anti-lock ring (if removed) and the differential ring gear on the differential case.

Fig 8: Locating Anti-Lock Ring

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Install the new 12 differential ring gear bolts.
- Apply stud and bearing mount to the differential ring gear bolts.
- Tighten to 150 Nm (111 lb-ft).

Fig 9: Identifying 12 Differential Ring Gear Bolts

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Install the differential assembly in the axle housing.

Fig 10: View Of Differential Assembly In Axle Housing

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NOTE: Install the differential bearing shims with the chamfer facing outboard.

Install a differential bearing shim on the LH side.

Fig 11: Identifying Differential Bearing Shim On Left Side

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NOTE: Index-mark the position of the differential bearing caps as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.

NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.

Install the LH differential bearing cap and loosely install the 2 differential bearing cap bolts.

Fig 12: Identifying LH Differential Bearing Cap And Bolts

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NOTE: Install the differential bearing shims with the chamfer facing outboard.

Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.

Fig 13: Identifying Differential Bearing Shim

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Install the RH side differential bearing cap and tighten the 2 LH side and 2 RH side differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).

Fig 14: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts

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Rotate the differential assembly to make sure it rotates freely.

Fig 15: Rotating Differential Assembly

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NOTE: If ring gear backlash is within specification, go to Step 21.

NOTE: Specification shown is the maximum ring gear backlash allowable.

Using the special tools, measure ring gear backlash.
- Turn the ring gear without turning the pinion gear and record the measurement.

Fig 16: Measuring Ring Gear Backlash Using Special Tools

Courtesy of FORD MOTOR CO.

NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.

To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.

If ring gear 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.

Backlash Change Required		Thickness Change Required
mm	In	mm	In
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

NOTE: Install the differential bearing shims with the chamfer facing outboard.

NOTE: The bearing caps must be removed before differential bearing shims can be installed.

To decrease ring gear backlash, install a thicker differential bearing shim on the LH side and a thinner differential bearing shim of the same thickness change on the RH side.

Fig 17: Identifying Differential Bearing Shims

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Rotate the differential assembly several times to make sure the differential bearings are seated.

Fig 18: Rotating Differential Assembly

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Using the special tools, recheck the ring gear backlash.

Fig 19: Measuring Ring Gear Backlash Using Special Tools

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Remove the 4 differential bearing cap bolts and the 2 differential bearing caps.

Fig 20: Locating Differential Bearing Cap Bolts

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NOTE: Install the differential bearing shims with the chamfer facing outboard.

NOTE: To establish differential bearing preload, increase both left and right differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.

Using the special tool, install the differential bearing shims.

Fig 21: Identifying Special Tool On Differential Bearing

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Install the 2 differential bearing caps and the 4 differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).

Fig 22: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts

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Apply high contrast hypoid gear marking compound and rotate the differential assembly 5 complete revolutions
Verify an acceptable pattern check.

NOTE: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the axle and the differential housing cover.
Install the axle shafts. For additional information, refer to Axle Shaft in this article.