Differential Carrier: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Position the differential assembly in the axle housing.

Fig 1: Positioning Differential Assembly In Axle Housing
Courtesy of FORD MOTOR CO.
Install the original removed differential bearing shims in their original positions.

Fig 2: Removing Differential Bearing Shims
Courtesy of FORD MOTOR CO.
Using the special tool, fully seat the differential bearing shims.

Fig 3: Using Special Tool Fully Seat Differential Bearing Shims
Courtesy of FORD MOTOR CO.
Install the differential bearing caps and the differential bearing cap bolts.
- Tighten to 119 Nm (88 lb-ft).
  
  Fig 4: Installing Differential Bearing Caps And Differential Bearing Cap
  Courtesy of FORD MOTOR CO.
Rotate the differential assembly to make sure it rotates freely.

Fig 5: Rotating Differential Assembly
Courtesy of FORD MOTOR CO.
Measure the ring and pinion backlash.
Install the axle shafts. Refer to AXLE SHAFT .
Install the differential cover and fill the axle with the specified fluid.