Differential Case: Installation

All vehicles 

CAUTION: If equipped, make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
Fig 1: Installing Ring Gear And Anti-Lock Speed Sensor On Differential Case
Courtesy 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 differential ring gear bolts.
   • Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the differential ring gear bolts.
     Fig 2: Installing Differential Ring Gear Bolts

     Courtesy of FORD MOTOR CO.
3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing.
4. Install a shim on the left side.
   Fig 3: Installing Shim On Left Side Of Ring Gear

   Courtesy of FORD MOTOR CO.
CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.
NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
Fig 4: Installing Left Bearing Cap Bolts
Courtesy 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 assembled by hand.
   Fig 5: Installing Larger Shims On Right Side Of Ring Gear

   Courtesy of FORD MOTOR CO.
7. Install the right side bearing cap, and tighten the bolts.
   Fig 6: Installing Right Side Bearing Cap And Tightening Bolts

   Courtesy of FORD MOTOR CO.
8. Rotate the differential case to make sure it rotates freely.
   Fig 7: Checking Rotation Of Differential Case

   Courtesy of FORD MOTOR CO.
9. Using the special tool, measure differential 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 the 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 8: Measuring Differential Ring Gear Backlash

     Courtesy 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. Check backlash. Repeat Step 9.
    Fig 9: Ring Gear Backlash And Thickness Changing Specification Chart (1 Of 2)

    Courtesy of FORD MOTOR CO.
    Fig 10: Ring Gear Backlash And Thickness Changing Specification Chart (2 Of 2)

    Courtesy 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 Thicker And Thinner Shim

      Courtesy of FORD MOTOR CO.
12. Install the bearing caps and bearing cap bolts.
    Fig 12: Installing Bearing Caps Bolts

    Courtesy of FORD MOTOR CO.
13. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 13: Checking Differential Bearings Correctly Seated

    Courtesy of FORD MOTOR CO.
14. Using the special tool check the backlash.
    • If backlash is within specification, go to backlash within specification in this procedure. If not, go to backlash not within specification within this procedure.
    • The specification shown in the illustration is the total allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 14: Checking Ring Gear Backlash

      Courtesy 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 a special tool, make sure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 15: Checking Proper Seating Of Differential Bearing Shims

      Courtesy of FORD MOTOR CO.
16. Install the bearing caps and bearing cap bolts.
    Fig 16: Installing Bearing Caps Bolts

    Courtesy of FORD MOTOR CO.
17. Using the special tool, verify the backlash.
    • The specification shown in the illustration is the total allowable range. For the preferred range, refer to SPECIFICATIONS .
    • For further adjustments, Refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
      Fig 17: Verifying Ring Gear Backlash

      Courtesy of FORD MOTOR CO.
18. Install the axle shafts. Refer to AXLE SHAFT .
NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to make sure the silicone sealant has cured correctly.
Fig 18: Tightening Differential Housing Cover Bolts
Courtesy of FORD MOTOR CO.
19. Install the differential housing cover and tighten the differential housing cover bolts.