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Differential Carrier: Installation

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.
    NOTE: Make sure the indicator needle is in the spreader adapter hole.
    Fig 1: Installing Special Tools
    G03928412Courtesy of FORD MOTOR CO.
  1. Install the special tools.
    2. CAUTION: Overspreading can damage the axle housing.
    Fig 2: Spreading Axle Housing To Specification
    G03928413Courtesy of FORD MOTOR CO.
  2. Spread the axle housing to the specification.
    • Remove the dial indicator.
    3. CAUTION: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces can occur.
    Fig 3: Positioning Differential Bearing Shims
    G03928414Courtesy of FORD MOTOR CO.
  3. Position the differential bearing shims.
    1. Apply a light coating of grease to one side of the differential bearing shims to help hold them in place.
    2. Position the differential bearing shims.
    4. NOTE: Push the differential carrier downward to fully seat the differential bearing cups in the axle housing.
    Fig 4: Positioning Differential Carrier
    G03928415Courtesy of FORD MOTOR CO.
  4. Position the differential carrier.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential assembly in place between the differential bearing shims.
  5. Install the differential bearing caps in their original positions and tighten with the housing still spread.
    1. Position the differential bearing caps.
    2. Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    3. Remove the special tool.
    Fig 5: Installing Differential Bearing Caps In Their Original Positions And Tightening With Housing Still Spread
    G03928416Courtesy of FORD MOTOR CO.
  6. Install the special tool.
    Fig 6: Installing Special Tool
    G03928417Courtesy of FORD MOTOR CO.
  7. Using the special tools, measure the differential ring gear backlash at 4 equally spaced points.
    1. Attach the special tool.
    2. Position the special tool tip centrally on a drive tooth.
    3. Zero the indicator.
    4. Turn the differential ring gear without turning the drive pinion gear.
    Fig 7: Using Special Tools To Measure Differential Ring Gear Backlash At 4 Equally Spaced Points
    G03927974Courtesy of FORD MOTOR CO.
  8. Install a new retainer circlip on each axle shaft.
    Fig 8: Installing New Retainer Circlip On Each Axle Shaft
    G03928312Courtesy of FORD MOTOR CO.
  9. Insert the axle shafts and engage them with the differential side gears.
    Fig 9: Inserting Axle Shafts And Engaging Them With Differential Side Gears
    G03928313Courtesy of FORD MOTOR CO.
  10. Push in on the axle shafts until the retaining circlips expand in the differential side gears.
    Fig 10: Pushing On Axle Shafts Until Retaining Circlips Expand In Differential Side Gears
    G03928314Courtesy of FORD MOTOR CO.
  11. Remove the axle assembly from the special tool and place it on the bench.
    12. CAUTION: Remove all of the silicone gasket and make sure the machined surfaces are free of oil before applying the new silicone gasket.
    CAUTION: Install the differential housing cover within 15 minutes of applying the silicone gasket, or it will be necessary to remove and reapply silicone gasket. If possible, allow 1 hour before filling with lubricant to make sure the silicone gasket has cured.
    Fig 11: Filling Sealing Groove On Differential Housing Cover With Silicone Gasket
    G03928422Courtesy of FORD MOTOR CO.
  12. Fill the sealing groove on the differential housing cover with silicone gasket.
  13. Install the differential housing cover and the 10 differential housing cover bolts.
    • Tighten to 32 Nm (24 lb-ft).
    Fig 12: Installing Differential Housing Cover And 10 Differential Housing Cover Bolts
    G03928402Courtesy of FORD MOTOR CO.
  14. Fill the axle housing with axle lubricant and install the fill plug.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 13: Filling Axle Housing With Axle Lubricant
    G03928424Courtesy of FORD MOTOR CO.
  15. Install the axle assembly. For additional information, refer to AXLE ASSEMBLY .
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