Differential Case: Installation

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 Ring Gear On Differential Case
Courtesy 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 Bolts

   Courtesy 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

   Courtesy of FORD MOTOR CO.
4. Install a differential bearing shim on the left side.
   Fig 4: Installing Differential Bearing Shim (Left Side)

   Courtesy of FORD MOTOR CO.
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 And Bolts
Courtesy 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 Progressively Larger Differential Bearing Shims

   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

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

   Courtesy 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  14. The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
   • If a zero backlash condition occurs, refer to  10.
   • If backlash is not within the specification, refer 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 Differential Ring Gear Backlash Using Special Tools

   Courtesy of FORD MOTOR CO.
10. Zero Backlash
    
    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  9.
    Fig 10: Measuring Backlash (Zero Backlash)

    Courtesy 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 11: Removing Bearing Caps

    Courtesy of FORD MOTOR CO.
12. 12. Rotate the differential assembly several times to verify that the differential bearings seated correctly.
    Fig 12: Rotating Differential Assembly

    Courtesy of FORD MOTOR CO.
13. 13. Using the special tools, recheck the backlash.
    • If backlash is within the specification, refer to  14. If backlash is not within the specification, repeat  11.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
    Fig 13: Checking Backlash Using Special Tools

    Courtesy of FORD MOTOR CO.
14. Backlash Within Specification
    
    14. Remove the bolts and the bearing caps.
15. 15. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.
    Fig 14: Installing Differential Bearing Shim

    Courtesy of FORD MOTOR CO.
16. 16. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 15: Installing Differential Bearing Shims Using Special Tool

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

    Courtesy of FORD MOTOR CO.
18. 18. Using the special tools, recheck the backlash.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
    Fig 17: Checking Backlash Using Special Tools

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