Differential Case: Installation

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

     Courtesy 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 Case In Rear Axle Housing

   Courtesy of FORD MOTOR CO.
4. Install a differential bearing shim on the left side.
   Fig 3: Installing Differential Bearing Shim On Left Side

   Courtesy of FORD MOTOR CO.
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: Identifying LH Differential Bearing Cap
Courtesy 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 Differential Bearing Shims

   Courtesy of FORD MOTOR CO.
7. Install the right side bearing cap and tighten the left side and right side bolts to specification.
   Fig 6: Installing Right Side Bearing Cap

   Courtesy of FORD MOTOR CO.
8. Rotate the differential case to make sure it turns freely.
   Fig 7: Rotating Differential Carrier

   Courtesy of FORD MOTOR CO.

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 . The specification shown in Fig 8 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.
     SPECIAL TOOL(S) SPECIFICATION
     
     

     Backlash Change Required		Thickness Change Required
     mm	Inch	mm	Inch
     0.025	0.001	0.050	0.002
     0.050	0.002	0.050	0.002
     0.076	0.003	0.101	0.004
     0.101	0.004	0.152	0.006
     0.127	0.005	0.152	0.006
     0.152	0.006	0.203	0.008
     0.177	0.007	0.254	0.010
     0.203	0.008	0.254	0.010
     0.228	0.009	0.304	0.012
     0.254	0.010	0.355	0.014
     0.279	0.011	0.355	0.014
     0.304	0.012	0.406	0.016
     0.330	0.013	0.457	0.018
     0.335	0.014	0.457	0.018
     0.381	0.015	0.508	0.020

     Fig 8: Measuring Differential Ring Gear Backlash

     Courtesy of FORD MOTOR CO.

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 .
    Fig 9: Locating Bearing Caps

    Courtesy 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 10: Locating Bearing Caps

      Courtesy of FORD MOTOR CO.
12. Rotate the differential assembly several times to verify that the differential bearings seated correctly.
    Fig 11: Rotating Differential Carrier

    Courtesy of FORD MOTOR CO.
13. Using the special tools, recheck the backlash.
    • If backlash is within the specification, refer to BACKLASH WITHIN SPECIFICATION . If backlash is not within the specification, repeat Backlash Not Within Specification in this procedure.
    • The specification shown in Fig 12is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 12: Rechecking Backlash

      Courtesy of FORD MOTOR CO.

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 in Fig 13.
    Fig 13: Removing Bolts And Bearing Caps

    Courtesy of FORD MOTOR CO.
16. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 14: Rotating Seat Differential Bearing Shims

    Courtesy of FORD MOTOR CO.
17. Install the bearing caps and bolts.
    Fig 15: Installing Bearing Caps And Bolts

    Courtesy of FORD MOTOR CO.
18. Using the special tools, recheck the backlash.
    • The specification shown in Fig 16 is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 16: Rechecking Backlash

      Courtesy of FORD MOTOR CO.
19. Install the axle shafts. For additional information, refer to AXLE SHAFT ..