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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 450 (Rear Drive Axle/Differential - Ford 7.5" Ring Gear) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

    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
    G03272283Courtesy of FORD MOTOR CO.
  1. Press a new anti-lock speed sensor ring, if removed, and the ring gear on the differential case.
    2. NOTE: Apply stud and bearing mount to the ring gear bolts.
    Fig 2: Installing Ring Gear Bolts
    G03272284Courtesy 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: Installing Differential Case In Rear Axle Housing
    G03272285Courtesy of FORD MOTOR CO.
  4. Install a (nominal) shim on the left side.
    Fig 4: Installing Shim - Left Side
    G03272286Courtesy of FORD MOTOR CO.
    5. 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
    G03272287Courtesy 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
    G03272288Courtesy 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 - Tightening All Bearing Cap Bolts
    G03272289Courtesy of FORD MOTOR CO.
  8. Rotate the differential case to make sure it rotates freely.
    Fig 8: Rotating Differential Case
    G03272290Courtesy of FORD MOTOR CO.

    9. 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 Zero backlash in this procedure.
    • If the backlash is not within specification, go to Backlash not within specification.
      MATERIAL SPECIFICATION

      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 Backlash
      G03272291Courtesy 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. Check the backlash. Repeat Measuring backlash in this procedure.

    11. Backlash Not Within Specification 

  11. 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: Locating Bearing Shim
      G03272292Courtesy of FORD MOTOR CO.
  12. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 11: Rotating Differential
    G03272293Courtesy of FORD MOTOR CO.

    13. BACKLASH WITHIN SPECIFICATION 

  13. Using the special tools, recheck the backlash.
    • If the backlash is not within specification, go to Backlash not within specification in this procedure.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 12: Measuring Backlash
      G03272294Courtesy 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 Fig 13.
    • Using the special tool, ensure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 13: Seating Differential Bearing Shims
      G03272295Courtesy of FORD MOTOR CO.
  15. Install the bearing caps and bearing cap bolts.
    Fig 14: Installing Bearing Caps
    G03272296Courtesy of FORD MOTOR CO.
  16. Using the special tool, recheck the backlash.
  17. Install the axle shafts. For additional information, refer to AXLE SHAFT .
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