Differential Case: Installation

All Vehicles 

CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor are aligned.
Fig 1: Installing Anti-Lock Speed Sensor Ring & Ring Gear
Courtesy of FORD MOTOR CO.
1. Press a new anti-lock speed sensor ring, if removed, and the ring gear on the differential case.
NOTE: Apply stud and bearing mount to the ring gear bolts.
Fig 2: Installing Ring Gear Bolts
Courtesy of FORD MOTOR CO.
2. Install the ring gear bolts.
3. With pinion depth set and pinion installed, place the differential case in the rear axle housing.
   Fig 3: Placing Differential Case In Rear Axle Housing

   Courtesy of FORD MOTOR CO.
4. Install a (nominal) shim on the left side.
   Fig 4: Installing (Nominal) Shim On Left Side

   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 cup is seated.
Fig 5: Installing Left Bearing Cap
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 6: Installing Progressively Larger Shims On Right Side

   Courtesy 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 & Bolts

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

   Courtesy of FORD MOTOR CO.

   Measuring Backlash 

9. Using the special tools, measure the ring gear backlash.
   • If the backlash is within specification, go to Backlash within specification. The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS  .
   • If a zero backlash condition occurs, go to  10 .
   • If the backlash is not within specification, go to  11 .
   BACKLASH SPECIFICATIONS
   
   

   Backlash Change Required		Thickness Change Required
   mm	Inch	mm	Inch
   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

   Fig 9: Measuring Ring Gear Backlash Using Special Tools

   Courtesy of FORD MOTOR CO.
10. Zero Backlash
    
    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. Check the backlash. Repeat Measuring backlash in this procedure.
11. Backlash Not Within Specification
    
    To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown.
    • If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.
    Fig 10: Removing Bearing Caps

    Courtesy of FORD MOTOR CO.
12. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 11: Rotating Differential

    Courtesy of FORD MOTOR CO.
13. Backlash Within Specification
    
    Using the special tools, recheck the backlash.
    • If the backlash is not within specification, go to  11 .
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS  .
    Fig 12: Measuring Backlash

    Courtesy of FORD MOTOR CO.
14. 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 the special tool, ensure the differential bearing shims are fully seated and the assembly turns freely.
    Fig 13: Verifying Bearing Shims Are Fully Seated

    Courtesy of FORD MOTOR CO.
15. Install the bearing caps and bearing cap bolts.
    Fig 14: Installing Bearing Caps & Bolts

    Courtesy of FORD MOTOR CO.
16. Using the special tool, recheck the backlash.
    • For additional adjustments, REFER to DRIVELINE SYSTEM-GENERAL INFORMATION .
    Fig 15: Measuring Backlash

    Courtesy of FORD MOTOR CO.
17. Install the axle shafts. For additional information, refer to AXLE SHAFT  .