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Differential Case Runout Check

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.
Special Tools

Illustration Tool Name Tool Number
GF0003210
 Dial Indicator 100-D005 (D78P-4201-G) or equivalent
GF0003211
 Dial Indicator Gauge Brackets 100-D004 (D78P-4201-F) or equivalent
GF0000024
 Dial Indicator With Holding Fixture 100-002 (TOOL-4201-C)
GF0000771
 Gauge, Clutch Housing 308-021 (T75L-4201-A)
GF0003212
 Spreader, Differential Carrier 205-001 (TOOL-4000-E)
  1. Position the special tool on the spreader adapters.
    Fig 1: Positioning Special Tool On Spreader Adapters
    GF0003213Courtesy of FORD MOTOR CO.
  2. Install the special tools.
    • Position the adapter tip in the spreader adapter hole.
    Fig 2: Identifying Special Tools
    GF0003214Courtesy of FORD MOTOR CO.
    3. CAUTION: Overspreading can damage the axle housing.
    Fig 3: Spreading Axle Housing To Specification
    GF0003215Courtesy of FORD MOTOR CO.
  3. Spread the axle housing to the specification.
    • Adjust the special tool to zero.
    • Tighten the housing spreader screw to spread the axle housing to the specification.
    • Remove the special tool.
    4. NOTE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the differential bearing caps in their original positions.
    Fig 4: Identifying Differential Bearing Cap Bolts
    GF0003216Courtesy of FORD MOTOR CO.
  4. Mark and remove the differential bearing caps.
    • Remove the 4 differential bearing cap bolts.
    • Remove the differential bearing caps.
    5. CAUTION: Use wood blocks to avoid axle housing damage.
    Fig 5: Removing Differential Assembly From Axle Housing
    G03912955Courtesy of FORD MOTOR CO.
  5. Remove the differential assembly from the axle housing.
    • Position the wood blocks.
    • Position and push down on the 2 pry bars.
    • Remove the differential assembly.
    • Remove the special tool.
  6. Remove and discard the 10 differential ring gear bolts and the differential ring gear.
    • Use a drift punch to separate the differential ring gear from the differential case.
    Fig 6: Identifying Differential Ring Gear Bolts
    GF0003217Courtesy of FORD MOTOR CO.
    7. NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating differential bearing overheating or failure.
    NOTE: It may be necessary to use the differential carrier spreader to carry out this step.
    Fig 7: Identifying Differential Bearing Cap Bolts
    GF0003218Courtesy of FORD MOTOR CO.
  7. Install the differential case with the differential bearing cups and all the shims in the housing.
    • Position the differential case with the differential bearing cups and shims in their original locations.
    • Install the 2 differential bearing caps.
    • Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    • Rotate the differential assembly to make sure the differential bearings have seated correctly.
  8. Install the special tool.
    Fig 8: Identifying Special Tool
    GF0003219Courtesy of FORD MOTOR CO.
  9. Rotate the differential assembly and check the differential case runout.
    • If the runout does not exceed the specification, install a new differential ring gear and pinion.
    • If runout exceeds the specification, install a new differential case.
      • Always install new differential bearings when installing a new differential case or if a bearing condition is questionable.
    Fig 9: Identifying Differential Case Runout Specification
    GF0003220Courtesy of FORD MOTOR CO.
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