Differential Case: Installation

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

Using the special tool, install the new differential bearings.
1. Position the bearings.
2. Using the special tool, press the bearings on the differential case.
  
  Fig 1: Installing Differential Bearings
  Courtesy of FORD MOTOR CO.
Position the differential ring gear and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.

Fig 2: Pressing Differential Ring Gear Onto Differential Case
Courtesy of FORD MOTOR CO.

NOTE: Clean the threads of the ring gear bolts. Make sure they are free of foreign material.

Install the bolts.
- Apply stud and bearing mount to the bolt threads.
  - Tighten to 114 Nm (84 lb-ft).
    
    Fig 3: Identifying Differential Ring Gear Bolts
    Courtesy of FORD MOTOR CO.
With the pinion depth set and pinion installed, place the differential assembly in the differential housing.

Fig 4: View Of Differential Assembly In Axle Housing
Courtesy of FORD MOTOR CO.
Install a differential bearing shim on the left side.

Fig 5: Identifying Differential Bearing Shim On Left Side
Courtesy of FORD MOTOR CO.

CAUTION: Always install the differential bearing caps in their identified locations and positions.

NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly.

Fig 6: Identifying LH Differential Bearing Cap And Bolts

Courtesy of FORD MOTOR CO.

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

Fig 7: Identifying Differential Bearing Shim
Courtesy of FORD MOTOR CO.
Install the right side differential bearing cap and tighten the left side and right side bolts.
- Tighten to 114 Nm (84 lb-ft).
  
  Fig 8: Identifying Bearing Caps & Bolts
  Courtesy of FORD MOTOR CO.
Rotate the differential case to make sure it turns freely.

Measuring backlash

Using the special tools, measure and note the differential ring gear backlash.

If backlash is within the specification, refer to Backlash within specification in this procedure. See step 15.
If a zero backlash condition occurs, refer to Zero backlash in this procedure. See step 11.
If backlash is not within the specification, refer to Backlash not within specification in this procedure. See step 12.

BACKLASH ADJUSTMENT CHART

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

Fig 9: Measuring Differential Ring Gear Backlash

Courtesy of FORD MOTOR CO.

Zero backlash

If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Measure the backlash. See step 10.

Fig 10: Locating Bearing Caps
Courtesy of FORD MOTOR CO.

Backlash not within specification

To increase or decrease backlash, remove the differential bearing caps and install a thicker shim and a thinner shim accordingly.
- If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.
  
  Fig 11: Locating Bearing Caps
  Courtesy of FORD MOTOR CO.
Rotate the differential assembly several times to verify that the differential bearings seated correctly.
Using the special tools, recheck the backlash.
- If backlash is within the specification, refer to Backlash Within Specification in this procedure. See step 15. If backlash is not within the specification, repeat Backlash not within specification in this procedure. See step 12.
  
  Fig 12: Measuring Differential Ring Gear Backlash
  Courtesy of FORD MOTOR CO.

Backlash within specification

Remove the bolts and the differential bearing caps.
To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.

Fig 13: Identifying Correct Differential Bearing Shim
Courtesy of FORD MOTOR CO.
Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.

Fig 14: Seating Differential Bearing Shims Using Special Tool
Courtesy of FORD MOTOR CO.
Install the differential bearing caps and bolts.
- Tighten to 114 Nm (84 lb-ft).
  
  Fig 15: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Using the special tools, recheck the backlash.

Fig 16: Measuring Differential Ring Gear Backlash
Courtesy of FORD MOTOR CO.

WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .

Install the axle shafts. For additional information, refer to AXLE SHAFT .