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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 778 (Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

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    All vehicles 

    CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.
    Fig 1: Positioning Differential Ring Gear
    G03884376Courtesy 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 sealer to the ring gear bolts.
      Fig 2: Installing Ring Gear Bolts
      G03884377Courtesy 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
    G03884378Courtesy of FORD MOTOR CO.
  4. Install a shim on the left side, of the specification shown in Fig 4.
    Fig 4: Installing Shim On Left Side
    G03884379Courtesy of FORD MOTOR CO.
    5. CAUTION: The bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
    Fig 5: Identifying Bearing Cap/Bolts
    G03884380Courtesy 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 inserted by hand.
    Fig 6: Installing Progressively Larger Shims On Right Side
    G03884381Courtesy of FORD MOTOR CO.
  7. Install the right side bearing cap and tighten the bolts.
    Fig 7: Installing Right Side Bearing Cap Bolts
    G03884382Courtesy of FORD MOTOR CO.
  8. Rotate the differential case to make sure it rotates freely.
    Fig 8: Rotating Differential Case To Make Sure It Rotates Freely
    G03884363Courtesy of FORD MOTOR CO.

    9. Measure backlash 

  9. Using the special tool, measure ring gear backlash.

    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. Go to MEASURE BACKLASH .
    BACKLASH 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

    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 10: Installing Thicker Shim And Thinner Shim
      G03884385Courtesy of FORD MOTOR CO.
  12. Install the bearing caps and bearing cap bolts.
    Fig 11: Installing Bearing Caps And Bearing Cap Bolts
    G03884382Courtesy of FORD MOTOR CO.
  13. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 12: Inspecting Differential Bearings Are Correctly Seated
    G03884363Courtesy of FORD MOTOR CO.
  14. Using the special tool, recheck the backlash.

    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 Fig 14.
    • Using the special tool, make sure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 14: Inspecting Differential Bearing Shims Are Fully Seated
      G03884389Courtesy of FORD MOTOR CO.
  16. Install the bearing caps and bearing cap bolts.
    Fig 15: Installing Bearing Caps And Bearing Cap Bolts
    G03884382Courtesy of FORD MOTOR CO.
  17. Use the special tool to verify the backlash.
    • The specification shown in Fig 16 is the total allowable range. For the preferred range, refer to the SPECIFICATIONS .
      Fig 16: Checking Backlash
      G03884384Courtesy of FORD MOTOR CO.
  18. Install the axle shafts. For additional information, refer to AXLE SHAFT .
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