Differential Case Runout Check

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.

SPECIAL TOOLS

	Spreader, Differential Carrier 205-001 (TOOL-4000-E)
	Dial Indicator Gauge Brackets 100-D004 (D78P-4201-F) or equivalent
	Dial Indicator 100-D005 (D78P-4201-G) or equivalent
	Gauge, Clutch Housing 308-021 (T75L-4201-A)
	Dial Indicator With Holding Fixture 100-002 (TOOL-4201-C)
	2-Jaw Puller 205-D072 (D97L-4221-A) or equivalent
	Step Plate 205-D061 (D83T-4205-C2)
	Installer, Differential Side Bearing 205-010 (T57L-4221-A2)

Position the special tool on the spreader adapters.

Fig 1: Positioning Special Tool On Spreader Adapters
Courtesy of FORD MOTOR CO.
Install the special tools.
- Position the adapter tip in the spreader adapter hole.
Fig 2: Installing Special Tools
Courtesy of FORD MOTOR CO.

CAUTION: Overspreading can damage the axle housing.

Fig 3: Spreading Axle Housing To Specification

Courtesy of FORD MOTOR CO.

Spread the axle housing to the specification.
1. Adjust the special tool to zero.
2. Tighten the housing spreader screw to spread the axle housing to the specification.
3. Remove the special tool.

CAUTION: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the differential bearing caps in their original positions.

Fig 4: Marking And Removing Differential Bearing Caps

Courtesy of FORD MOTOR CO.

Mark and remove the differential bearing caps.
1. Remove the 4 differential bearing cap bolts.
2. Remove the differential bearing caps.

CAUTION: Use wood blocks to avoid axle housing damage.

Fig 5: Removing Differential Assembly From Axle Housing

Courtesy of FORD MOTOR CO.

Remove the differential assembly from the axle housing.
1. Position the wood blocks.
2. Position and push down on the two pry bars.
3. Remove the differential assembly.
4. Remove the special tool.
Remove the 10 differential ring gear bolts and the differential ring gear.
- Use a drift punch to separate the differential ring gear from the differential case.
Fig 6: Removing 10 Differential Ring Gear Bolts And Differential Ring Gear
Courtesy of FORD MOTOR CO.

NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating differential bearing overheating or failure.

NOTE: It may be necessary to use the differential carrier spreader to carry out this step.

Fig 7: Installing Differential Case With Differential Bearing Cups And All Shims In Housing

Courtesy of FORD MOTOR CO.

Install the differential case with the differential bearing cups and all the shims in the housing.
1. Position the differential case with the differential bearing cups and shims in their original locations.
2. Install the differential bearing caps.
3. Install the 4 differential bearing cap bolts.
  - Tighten to 105 Nm (77 lb-ft).
4. Rotate the differential assembly to make sure the differential bearings have seated correctly.
Install the special tool.

Fig 8: Installing Special Tool
Courtesy of FORD MOTOR CO.
Rotate the differential assembly and check the differential case runout.
- If the runout does not exceed the specification, install a new differential ring gear and pinion.
- If runout exceeds the specification, install a new differential case.
  - Always install new differential bearings when installing a new differential case, or if a bearing condition is questionable.
Fig 9: Rotating Differential Assembly And Checking Differential Case Runout
Courtesy of FORD MOTOR CO.