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Home >> Ford >> 2000 >> Focus ZTS, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 1156 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- F250-F350 Super Duty) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: 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.

    All vehicles 

  1. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case.
    • Tighten to 150 Nm (110 lb-ft).
      Fig 1: Pressing Anti-Lock Speed Sensor Onto Differential Case
      G03883502Courtesy of FORD MOTOR CO.
  2. Using special thread sealant, install the ring gear bolts.
    • Tighten to 150 Nm (110 lb-ft).
      Fig 2: Identifying Ring Gear Bolts
      G03883503Courtesy of FORD MOTOR CO.
  3. With the pinion depth set and the pinion installed, place the differential case in the rear axle housing.
    • Install a shim on the left side as shown in the illustration.
      Fig 3: Installing Differential Bearing Shim On Left Side
      G03878553Courtesy of FORD MOTOR CO.
    4. CAUTION: The bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left bearing is seated.
    Fig 4: Identifying Bearing Cap/Bolts
    G03884380Courtesy of FORD MOTOR CO.
  4. Install the left bearing cap and loosely install the bearing cap bolts.
  5. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
    Fig 5: Installing Larger Shims On Right Side
    G03904498Courtesy of FORD MOTOR CO.
  6. Install the right side bearing cap and tighten the bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 6: Installing Right Side Bearing Cap
      G03904556Courtesy of FORD MOTOR CO.
  7. Rotate the differential case to make sure it rotates freely.
    Fig 7: Rotating Differential
    G03904430Courtesy of FORD MOTOR CO.

    8. Measuring backlash 

  8. Using the special tool, measure ring gear backlash.
    • If the backlash is within specification, go to  14, Backlash Within Specification  . The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
    • If a zero backlash condition occurs, go to  9, Zero Backlash  .
    • If the backlash is not within specification, go to  10Backlash Not Within Specification  .
      Fig 8: Checking Ring Gear Backlash
      G03904558Courtesy of FORD MOTOR CO.

    9. Zero backlash 

  9. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step  8.
    BACKLASH AND THICKNESS SPECIFICATION

    Backlash Change Required Thickness Change Required
    mm Inch mm Inch
    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

    10. Backlash not within specification 

  10. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim as shown.
    • If 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.
      Fig 9: Removing Bearing Caps
      G03904502Courtesy of FORD MOTOR CO.
  11. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 10: Installing Bearing Caps And Bearing Cap Bolts
      G03904556Courtesy of FORD MOTOR CO.
  12. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 11: Rotating Differential
    G03904430Courtesy of FORD MOTOR CO.
  13. Using the special tool, recheck the backlash.
    • If backlash is within specification, go to  14, Backlash Within Specification  . If not, repeat Step  8.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 12: Measuring Ring Gear Backlash
      G03884451Courtesy of FORD MOTOR CO.

    14. Backlash within specification 

  14. Remove the bearing caps and bolts.
    • To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
    • Using the special tool, make sure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 13: Installing Differential Bearing Shims
      G03904436Courtesy of FORD MOTOR CO.
  15. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 14: Identifying Differential Bearing Caps And Bolts
      G03878679Courtesy of FORD MOTOR CO.
  16. Using the special tool, verify the backlash.
    Fig 15: Measuring Ring Gear Backlash
    G03884451Courtesy of FORD MOTOR CO.
  17. Install the axle shafts. For additional information, refer to AXLE SHAFT .
    18. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
  18. Clean the gasket mating surface of the rear axle and the differential housing cover.
  19. Apply a new, continuous bead of silicone sealant to the differential housing cover.
    Fig 16: Applying A New Continuous Bead Of Sealant To Differential Housing Cover
    G03878622Courtesy of FORD MOTOR CO.
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