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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 579 (Rear Drive Axle/Differential - Ford 8.8" Ring Gear) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

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    ALL AXLES 

  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 1: Installing Bolts
    G02760871Courtesy of FORD MOTOR CO.
  3. With the pinion depth set and pinion installed, place the differential assembly in the differential housing.
    Fig 2: Placing Differential Assembly In Differential Housing
    G02760872Courtesy of FORD MOTOR CO.
  4. Install a differential bearing shim on the left side.
    Fig 3: Installing A Differential Bearing Shim On Left Side
    G02760873Courtesy 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 4: Installing Left Bearing Cap Bolts
    G02760874Courtesy 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 can be installed by hand.
    Fig 5: Installing Progressively Larger Differential Bearing Shims On Right Side
    G02760875Courtesy of FORD MOTOR CO.
  7. Install the right side bearing cap and tighten the left side and right side bolts to specification.
    Fig 6: Identifying Tighten Torque Of Bearing Cap Bolts
    G02760876Courtesy of FORD MOTOR CO.
  8. Rotate the differential case to make sure it turns freely.
    Fig 7: Rotating Differential Case
    G02760877Courtesy 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 in this procedure.
    • If backlash is not within the specification, refer to Backlash Not Within Specification in this procedure.
    Fig 8: Differential Ring Gear Backlash Shim Specifications
    G02760878Courtesy of FORD MOTOR CO.
    Fig 9: Measuring Differential Ring Gear Backlash
    G02760879Courtesy 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 Measuring Backlash in this procedure.
    Fig 10: Differential Bearing Shim Locations
    G02760880Courtesy of FORD MOTOR CO.

    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: Differential Bearing Shim Locations
    G02760881Courtesy of FORD MOTOR CO.
  12. Rotate the differential assembly several times to verify that the differential bearings seated correctly.
    Fig 12: Rotating Differential Assembly Several Times To Verify That Differential Bearings Seated Correctly
    G02760882Courtesy 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 13: Measuring Differential Ring Gear Backlash
    G02760883Courtesy of FORD MOTOR CO.

    14. 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.
    Fig 14: Increasing Both Left And Right Differential Bearing Shim Sizes By Specification Shown
    G02760884Courtesy of FORD MOTOR CO.
  16. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 15: Seating Differential Bearing Shims
    G02760885Courtesy of FORD MOTOR CO.
  17. Install the bearing caps and bolts.
    Fig 16: Installing Bearing Caps Bolts
    G02760886Courtesy 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 17: Checking Backlash
    G02760887Courtesy of FORD MOTOR CO.
  19. Install the axle shafts. For additional information, refer to AXLE SHAFT .
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