LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 723 (Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. 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 ring are aligned.
    Fig 1: Pressing Ring Gear
    G01440652Courtesy of FORD MOTOR CO.
  1. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case.
  2. Install the bolts.
    • Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts.
    Fig 2: Installing Ring Gear Bolts
    G01440653Courtesy of FORD MOTOR CO.
  3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing.
    Fig 3: Placing Differential Case In Rear Axle Housing
    G01440654Courtesy of FORD MOTOR CO.
  4. Install a shim on the left side.
    Fig 4: Installing Shim On Left Side
    G01440655Courtesy 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 position.
    NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
    Fig 5: Installing Left Bearing Cap
    G01440656Courtesy 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 Larger Shims On Right Side
    G01440657Courtesy of FORD MOTOR CO.
  7. Install the right side bearing cap, and tighten the bolts.
    Fig 7: Installing Right Side Bearing Cap
    G01440658Courtesy of FORD MOTOR CO.
  8. Rotate the differential case to make sure it rotates freely.
    Fig 8: Rotating Differential Case For Checking Freely Movement
    G01440659Courtesy of FORD MOTOR CO.

    9. MEASURE BACKLASH 

  9. Using the special tool, measure ring gear backlash.
    • If the backlash is within specification, go to BACKLASH WITHIN SPECIFICATION in this procedure. The specification shown in the illustration is the total allowable range. For the preferred range, refer to the SPECIFICATIONS  portion of this article.
    • 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 in this procedure.
    Fig 9: Measuring Ring Gear Backlash
    G01440660Courtesy of FORD MOTOR CO.

    10. ZERO BACKLASH 

  10. If a zero backlash condition occurs, add a 0.50-mm (0.020-inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Go to MEASURE BACKLASH in this procedure.
    Fig 10: Ring Gear Backlash Specification Chart (1 Of 2)
    G01440661Courtesy of FORD MOTOR CO.
    Fig 11: Ring Gear Backlash Specification Chart (2 Of 2)
    G01440662Courtesy of FORD MOTOR CO.

    11. BACKLASH NOT WITHIN SPECIFICATION 

  11. To increase or decrease backlash, remove the bearing caps, and install a thicker shim and a thinner shim as shown.
    • If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
    Fig 12: Installing Thicker And Thinner Shim
    G01440663Courtesy of FORD MOTOR CO.
  12. Install the bearing caps and bearing cap bolts.
    Fig 13: Installing Bearing Caps Bolts
    G01440664Courtesy of FORD MOTOR CO.
  13. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 14: Rotating Differential Several Times for Checking Differential Bearings Correctly Seating
    G01440665Courtesy of FORD MOTOR CO.
  14. Using the special tool, recheck the backlash.
    • If backlash is within specification, go to Backlash Within Specification in this procedure. If not, go to Measure backlash in this procedure.
    • The specification shown in the illustration is the total allowable range. For the preferred range, refer to the SPECIFICATIONS  portion of this article.
    Fig 15: Rechecking Ring Gear Backlash
    G01440666Courtesy of FORD MOTOR CO.

    15. BACKLASH WITHIN SPECIFICATION 

  15. Remove the bearing caps and bolts.
    • To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
    • Using the special tool, make sure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 16: Installing Differential Bearing Shims
      G01440667Courtesy of FORD MOTOR CO.
  16. Install the bearing caps and bearing cap bolts.
    Fig 17: Installing Bearing Caps Bolts
    G01440668Courtesy of FORD MOTOR CO.
  17. Use the special tool to verify the backlash.
    • The specification shown in the illustration is the total allowable range. For the preferred range, refer to the SPECIFICATIONS  portion of this article.
    Fig 18: Verifying Ring Gear Backlash
    G01440669Courtesy of FORD MOTOR CO.
  18. Install the axle shafts. For additional information, refer to AXLE SHAFT .
scientia non olet · About LEMON Manuals