Differential Case and Ring Gear - Conventional: Assembly

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

Position the differential side gear thrust washers on the differential side gears.
- Lubricate the differential side gear thrust washers and the differential side gear journals with axle lubricant.
Fig 1: Identifying Differential Thrust Washers & Differential Side Gears
Courtesy of FORD MOTOR CO.
Position the differential side gears.

Fig 2: Positioning Differential Side Gears
Courtesy of FORD MOTOR CO.
Assemble the differential pinion gear thrust washers and the differential pinion gears.
- Lubricate the washers and gears with rear axle lubricant.
Fig 3: Assembling Differential Pinion Gear Thrust Washers And Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Engage the differential pinion gears opposite the differential side gears.

Fig 4: Engaging Differential Pinion Gears Opposite Differential Side Gears
Courtesy of FORD MOTOR CO.
Rotate the differential pinion gears to align the differential pinion shaft bore.

Fig 5: Rotating Differential Pinion Gears To Align Differential Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.

Fig 6: Inserting Differential Pinion Shaft And Installing New Differential Pinion Shaft Lock Bolt Finger-Tight
Courtesy of FORD MOTOR CO.
If removed, use the special tool to install the differential bearings.

Fig 7: Installing Differential Bearings Using Special Tool
Courtesy of FORD MOTOR CO.
Press the new anti-lock ring (if removed) and the differential ring gear on the differential case.

Fig 8: Pressing New Anti-Lock Ring (If Removed) And Differential Ring Gear On Differential Case
Courtesy of FORD MOTOR CO.
Install the 12 differential ring gear bolts.
- Apply stud and bearing mount to the differential ring gear bolts.
- Tighten to 150 Nm (111 lb-ft).
Fig 9: Installing 12 Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.
Install the differential assembly in the axle housing.

Fig 10: Installing Differential Assembly In Axle Housing
Courtesy of FORD MOTOR CO.
Install a differential bearing shim on the LH side.

Fig 11: Installing Differential Bearing Shim On LH Side
Courtesy of FORD MOTOR CO.

CAUTION: Index mark the position of the differential bearing caps as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.

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

Fig 12: Installing LH Differential Bearing Cap And Loosely Installing Differential Bearing Cap Bolts

Courtesy of FORD MOTOR CO.

Install the LH differential bearing cap and loosely install the differential bearing cap bolts.
Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.

Fig 13: Installing Differential Bearing Shims On RH Side
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 14: Installing RH Side Differential Bearing Cap And Tightening LH Side And RH Side Differential Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
Rotate the differential assembly to make sure it rotates freely.

Fig 15: Rotating Differential Assembly To Make Sure It Rotates Freely
Courtesy of FORD MOTOR CO.

NOTE: If ring gear backlash is within specification, go to Step 21.

NOTE: Specification shown is the maximum ring gear backlash allowable.

Fig 16: Measuring Ring Gear Backlash Using Special Tools

Courtesy of FORD MOTOR CO.

Using the special tools, measure ring gear backlash.
- Turn the ring gear without turning the pinion gear and record the measurement.

NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.

Fig 17: Installing Thicker Differential Bearing Shim And Thinner Differential Bearing Shim

Courtesy of FORD MOTOR CO.

To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.

If ring gear 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.

BACKLASH ADJUSTMENT & DIFFERENTIAL BEARING SHIM THICKNESS SPECIFICATIONS

Backlash Change Required		Thickness Change Required
mm	in	mm	in
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

NOTE: The bearing caps must be removed before differential bearing shims can be installed.

Fig 18: Installing Thicker Differential Bearing Shim And Thinner Differential Bearing Shim Of Same Thickness

Courtesy of FORD MOTOR CO.

To decrease ring gear backlash, install a thicker differential bearing shim (A) and a thinner differential bearing shim of the same thickness (B) as shown.
Rotate the differential assembly several times to make sure the differential bearings are seated.

Fig 19: Rotating Differential Assembly Several Times To Make Sure Differential Bearings Are Seated
Courtesy of FORD MOTOR CO.
Using the special tools, recheck the ring gear backlash.

Fig 20: Rechecking Ring Gear Backlash Using Special Tools
Courtesy of FORD MOTOR CO.
Remove the differential bearing cap bolts (A) and differential bearing caps (B).

Fig 21: Removing Differential Bearing Cap Bolts And Differential Bearing Caps
Courtesy of FORD MOTOR CO.

NOTE: To establish differential bearing preload, increase both left and right differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.

Fig 22: Installing Differential Bearing Shims Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, install the differential bearing shims.
Install the differential bearing caps and differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).
Fig 23: Installing Differential Bearing Caps And Differential Bearing Cap Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the axle and the differential housing cover.
Apply a new, continuous bead of sealant to the differential housing cover.

Fig 24: Applying New Continuous Bead Of Sealant To Differential Housing Cover
Courtesy of FORD MOTOR CO.

NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has correctly cured.

Fig 25: Installing Differential Housing Cover And Differential Housing Cover Bolts

Courtesy of FORD MOTOR CO.

Install the differential housing cover and the differential housing cover bolts.
- Tighten to 45 Nm (33 lb-ft).

NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.

Fig 26: Checking Axle Lubricant Fill Level

Courtesy of FORD MOTOR CO.

Fill the axle to the level shown with axle lubricant and install the filler plug.
- Tighten to 30 Nm (22 lb-ft).