Differential Carrier: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Install the outboard spacer in its original location.

Fig 1: Identifying Outboard Spacers
Courtesy of FORD MOTOR CO.
Assemble the differential bearing cups to the differential bearings.

CAUTION: Do not spread the differential housing more than specified.

CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.

Using the special tools, spread the differential housing to the specification.
- Remove the dial indicator.
- Use a rawhide hammer to seat the differential into the differential housing pocket.
  - Remove the special tools.
    
    Fig 2: Using Special Tools To Spread Differential Housing
    Courtesy of FORD MOTOR CO.

CAUTION: Match the mating letters as noted during removal.

Install the bearing caps, aligning the letters with those on the differential housing.
- Tighten to 108 Nm (80 lb-ft).
  
  Fig 3: Installing Bearing Caps
  Courtesy of FORD MOTOR CO.
Using the special tools, measure the differential ring gear and pinion backlash at 3 equally spaced points.

Fig 4: Measuring Differential Ring Gear And Pinion Backlash
Courtesy of FORD MOTOR CO.
Install the axle shafts. For additional information, refer to AXLE SHAFT .
Install the differential housing cover.