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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 640 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the outboard spacers in the side from which they were removed.
    Fig 1: Installing Outboard Spacers
    G02768892Courtesy of FORD MOTOR CO.
    2. NOTE: Remove all nicks, burrs and dirt from the differential case hubs, to allow the special tools to rotate freely.
    Fig 2: Placing Special Tools Into Differential Case Hubs
    G02768893Courtesy of FORD MOTOR CO.
  2. Place the special tools of the differential case hubs and position the assembly into the differential housing.
    3. NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.
    Fig 3: Mounting Special Tool On Flat Surface Of Differential Case
    G02768894Courtesy of FORD MOTOR CO.
  3. Mount the special tools as shown. Locate the tip of the Clutch Housing Gauge on a flat surface of the differential case.
    4. NOTE: Repeat this and the following step until the same readings appear on the indicator each time. This is the total differential bearing shim thickness necessary, less preload. The final calculation occurs later during assembly.
    Fig 4: Forcing Differential Case Toward Indicator
    G02768895Courtesy of FORD MOTOR CO.
  4. Force the differential case as far as possible toward the indicator. With force applied, set the indicator at 0. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
  5. After making sure the reading is repeatable, remove the special tools and the differential case from the differential housing. Do not remove the Master Bearings from the differential case at this time.
    6. NOTE: Apply Threadlock® and Sealer to the new bolts.
    Fig 5: Applying Threadlock® And Sealer To Bolts
    G02768896Courtesy of FORD MOTOR CO.
  6. Start 2 bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and differential case align.
  7. Press the anti-lock speed sensor on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
    Fig 6: Pressing Anti-Lock Speed Sensor On Differential Case
    G02768897Courtesy of FORD MOTOR CO.
    8. NOTE: Apply Threadlock® and Sealer to the new bolt threads.
  8. Draw up the new ring gear bolts alternately and evenly to specifications.
    • Tighten to 298 Nm (220 lb-ft).
      Fig 7: Applying Threadlock® And Sealer To Bolt Threads
      G02768898Courtesy of FORD MOTOR CO.
  9. Install the outboard spacers in the side from which they were removed.
    Fig 8: Installing Outboard Spacers
    G02768899Courtesy of FORD MOTOR CO.
  10. Place the differential assembly with the special tools in the differential housing.
    Fig 9: Placing Differential Assembly Using Special Tools In Differential Housing
    G02768900Courtesy of FORD MOTOR CO.
  11. Install the special tools. Locate the tip of the Clutch Housing Gauge on the flat surface of one of the bolts.
    Fig 10: Installing Special Toulon Flat Surface Of Bolts
    G02768901Courtesy of FORD MOTOR CO.
    12. NOTE: Repeat this and the following step until the same readings appear on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.
    Fig 11: Forcing Differential Case And Ring Gear Away From Drive Pinion
    G02768902Courtesy of FORD MOTOR CO.
  12. Force the differential case and ring gear away from the drive pinion. With force applied, set the indicator to 0.
  13. Force the differential ring gear into mesh with the pinion to obtain an indicator reading. Record this measurement.
    Fig 12: Forcing Differential Ring Gear Into Mesh With Pinion
    G02768903Courtesy of FORD MOTOR CO.
  14. Remove the differential case and the special tools from the differential housing.
  15. Remove the Master Bearings from the differential case.
  16. Place a shim of the thickness determined by the end play between the differential case and the ring gear/pinion on the ring gear side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
  17. Using the special tool, install the differential bearing on the differential ring gear side of the differential case.
    Fig 13: Installing Differential Bearing Using Special Tool
    G02768904Courtesy of FORD MOTOR CO.
  18. Determine the correct shim thickness and place the shim on the differential case hub on the drive pinion side.
    • To determine the correct shim thickness, first subtract the thickness of the ring gear side differential case hub shim from the total differential case end play reading recorded earlier. Then, add 0.25 mm (0.010 in.) to this amount. This result is the correct thickness of shim to place on the pinion side differential hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
  19. Using the special tools, install the differential bearing.
    1. Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
    2. Using the special tool, drive the differential bearing onto the hub.
      Fig 14: Installing Differential Bearing Onto Hub Using Special Tool
      G02768905Courtesy of FORD MOTOR CO.
  20. Assemble the differential bearing cups to the differential bearings.
    21. CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.
  21. Using the special tools, spread the differential housing to specifications.
    • Use a rawhide hammer to seat the differential in the differential housing.
    • Remove the special tools.
      Fig 15: Spreading Differential Housing Using Special Tool
      G02768906Courtesy of FORD MOTOR CO.
    22. CAUTION: Match the mating letters as noted during disassembly.
    Fig 16: Aligning Mating Letters
    G02768907Courtesy of FORD MOTOR CO.
  22. Install the bearing caps, aligning the letters with those on the differential housing. Tighten to 108 Nm (80 lb-ft).
  23. Carry out the Tooth Contact Pattern Check to verify the final pinion position is correct. Refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
  24. Install the axle shafts. Refer to WHEEL HUBS & BEARINGS - FULL FLOATING AXLE - DANA .
    25. CAUTION: Clean both flat surfaces (differential housing and differential cover) with a suitable solvent to remove all traces of oil film.
    CAUTION: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.
  25. Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
  26. Place 2 bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover on the differential housing.
  27. Install the remaining bolts. Tighten the bolts alternately and evenly.
    • Tighten to 47 Nm (35 lb-ft).
    • Allow a 1 hour cure time before filling the axle with the correct amount of specified lubricant.
      Fig 17: Installing Differential Housing Cover Bolts
      G02768908Courtesy of FORD MOTOR CO.
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