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Differential Carrier - Front Axle: Installation

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the special tools.
    • Position the clutch housing gauge needle in the differential carrier spreader adapter hole.
    Fig 1: Installing Special Tools
    G03190433Courtesy of FORD MOTOR CO.
    2. CAUTION: Overspreading can damage the differential housing.
    Fig 2: Spreading Differential Housing To The Specification
    G03190434Courtesy of FORD MOTOR CO.
  2. Spread the differential housing to the specification.
  3. Remove the special tools.
    Fig 3: Removing Special Tools
    G03190435Courtesy of FORD MOTOR CO.
    4. NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the differential housing.
    Fig 4: Installing Differential Bearing Cups And The Differential Assembly
    G03190436Courtesy of FORD MOTOR CO.
  4. Install the differential bearing cups and the differential assembly in the differential housing.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential assembly in place.
    5. CAUTION: Do not tighten the differential bearing cap bolts to specification at this time.
    Fig 5: Installing Differential Bearing Cap
    G03190437Courtesy of FORD MOTOR CO.
  5. Install the differential bearing caps in their original positions.
    1. Position the differential bearing caps.
    2. Install the differential bearing cap bolts hand-tight.
  6. Remove the special tools.
  7. Tighten the differential bearing cap bolts.
    • Tighten to 61 Nm (45 lb-ft).
    Fig 6: Tightening Bearing Cap Bolts
    G03190438Courtesy of FORD MOTOR CO.
  8. Verify that the differential assembly rotates freely.
  9. Check the ring gear backlash and remove the special tools.
    Fig 7: Measuring Ring Gear Backlash Using Dial Indicator
    G03190439Courtesy of FORD MOTOR CO.
  10. Install the RH axle shaft.
    11. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.
    CAUTION: Install the differential housing cover within 15 minutes of applying the silicone material.
    CAUTION: Allow the sealant to cure for one hour before filling the axle with lubricant.
    Fig 8: Identifying Differential Housing Cover
    G03190440Courtesy of FORD MOTOR CO.
  11. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
  12. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 29 Nm (21 lb-ft).
  13. Install the axle assembly. For additional information, refer to FRONT AXLE ASSEMBLY .
  14. Fill the axle with Motorcraft SAE 80W-90 Premium Rear Axle Lubricant to 9.56 mm (0.38 in) below the bottom of the filler hole.
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