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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 315 (Drive Axle/Differential - 8.8-Inch Ring Gear) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    ALL AXLES 

    CAUTION: If installing a new anti-lock speed sensor ring, align the notch on the case flange and the tab on the anti-lock speed sensor ring.
    Fig 1: Pressing Differential Ring Gear On Differential Case
    G01440483Courtesy of FORD MOTOR CO.
  1. Position the differential ring gear, the anti-lock speed sensor ring, and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear. Press the new anti-lock speed sensor ring, if removed, and the differential ring gear on the differential case.
  2. Install the bolts.
    • Apply stud and bearing mount to the bolt threads.
    Fig 2: Installing Differential Ring Gear Bolts
    G01440484Courtesy of FORD MOTOR CO.
  3. With the pinion depth set and pinion installed, place the differential assembly in the differential housing.
    Fig 3: Placing Differential Assembly In Differential Housing
    G01440485Courtesy of FORD MOTOR CO.
  4. Install a differential bearing shim on the left side.
    Fig 4: Installing Differential Bearing Shim On Left Side
    G01440486Courtesy of FORD MOTOR CO.
    5. CAUTION: Always install the bearing caps in their identical locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly
    Fig 5: Installing Left Bearing Cap
    G01440487Courtesy of FORD MOTOR CO.
  5. Install the left bearing cap and loosely install the bolts.
  6. Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand.
    Fig 6: Installing Differential Bearing Shims On Right Side
    G01440488Courtesy of FORD MOTOR CO.
  7. Install the right side bearing cap and tighten the left side and right side bolts to specification.
    Fig 7: Installing Right Side Bearing Cap
    G01440489Courtesy of FORD MOTOR CO.
  8. Rotate the differential case to make sure it turns freely.
    Fig 8: Rotating Differential Case
    G01440490Courtesy of FORD MOTOR CO.

    9. MEASURING BACKLASH 

  9. Using the special tools, measure and note the differential ring gear backlash.
    • If backlash is within the specification, refer to Backlash Within Specification in this procedure. The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
    • If a zero backlash condition occurs, refer to Zero Backlash.
    • If backlash is not within the specification, refer to Backlash Not Within Specification.
      Fig 9: Differential Ring Gear Backlash Specification Chart (1 Of 2)
      G01440491Courtesy of FORD MOTOR CO.
      Fig 10: Differential Ring Gear Backlash Specification Chart (2 Of 2)
      G01440492Courtesy of FORD MOTOR CO.
      Fig 11: Measuring Differential Ring Gear Backlash
      G01440493Courtesy of FORD MOTOR CO.
  10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Measure the backlash. Refer to Measuring Backlash in this procedure.

    ZERO BACKLASH 

    Fig 12: Identifying Shim For Adjusting Backlash
    G01440494Courtesy of FORD MOTOR CO.

    11. BACKLASH NOT WITHIN SPECIFICATION 

  11. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim accordingly.
    • If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.
      Fig 13: Adjusting Shims For Increasing Or Decreasing Backlash
      G01440495Courtesy of FORD MOTOR CO.
  12. Rotate the differential assembly several times to verify that the differential bearings seated correctly.
    Fig 14: Rotating Differential Assembly
    G01440496Courtesy of FORD MOTOR CO.
  13. Using the special tools, recheck the backlash.
    • If backlash is within the specification, refer to BACKLASH WITHIN SPECIFICATION   in this procedure. If backlash is not within the specification, repeat BACKLASH NOT WITHIN SPECIFICATION  in this procedure.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
    Fig 15: Checking Differential Ring Gear Backlash
    G01440497Courtesy of FORD MOTOR CO.

    BACKLASH WITHIN SPECIFICATION 

  14. Remove the bolts and the bearing caps.
  15. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.
    16. Fig 16: Identifying Shim Location
    G01440498Courtesy of FORD MOTOR CO.
  16. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 17: Installing Differential Bearing Shims
    G01440499Courtesy of FORD MOTOR CO.
  17. Install the bearing caps and bolts.
    Fig 18: Installing Bearing Caps And Bolts
    G01440500Courtesy of FORD MOTOR CO.
  18. Using the special tools, recheck the backlash.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 19: Removing Differential Flange Bolts
      G01440502Courtesy of FORD MOTOR CO.
  19. Install the axle shafts. For additional information, refer to AXLE SHAFT .
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