Differential Carrier: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. 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: Placing Differential Case In Rear Axle Housing
Courtesy of FORD MOTOR CO.
Install the original differential bearing shim on the LH side.

NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.

Fig 2: Identifying LH Differential Bearing Cap

Courtesy of FORD MOTOR CO.

Install the LH differential bearing cap and loosely install the differential bearing cap bolts.
Install the original differential bearing shim on the RH side.

Fig 3: Installing Differential Bearing Shims
Courtesy of FORD MOTOR CO.
Using the special tool, fully seat the differential bearing shims.

Fig 4: Seating Differential Bearing Shims
Courtesy of FORD MOTOR CO.
Install the RH side differential bearing cap and tighten the LH side and RH side differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).
  
  Fig 5: Identifying Differential Bearing Caps And Differential Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Rotate the differential assembly to make sure it rotates freely.

Fig 6: Rotating Differential Carrier
Courtesy of FORD MOTOR CO.
Measure the ring and pinion backlash.
Install the axle shafts. For additional information, refer to AXLE SHAFT .