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Home >> Ford >> 2001 >> Excursion 5.4 L, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 284 (Rear Drive Axle/Differential - DANA S135 -- F450-F550 Super Duty) >> Disassembly And Assembly >> Differential Case and Ring Gear >> Assembly

Differential Case and Ring Gear: Assembly

WARNING: This page is about a different car, the 2003 Ford F550 Super Duty and 2003 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
  1. Assemble the differential ring gear and, if removed, a new anti-lock speed sensor ring to the differential case.
    1. Align the tab on the sensor ring with the notch in the case flange.
    2. Bolt the differential ring gear to the case in three places, 120 degrees apart.
      Fig 1: Assembling Differential Ring Gear And Anti-Lock Speed Sensor Ring
      G01551110Courtesy of FORD MOTOR CO.
    2. NOTE: Proceed to the next step of this procedure if not installing a new anti-lock speed sensor ring.
    Fig 2: Pressing Anti-Lock Speed Sensor Ring On Case Flange
    G01551111Courtesy of FORD MOTOR CO.
  2. Press the anti-lock speed sensor ring on the case flange.
    3. CAUTION: Compress the rivet before removing the bolts from the differential ring gear and case to prevent differential ring gear runout.
    Fig 3: Installing Rivet Using Suitable Hydraulic Or Mechanical Press And Riveting Fixture
    G01551112Courtesy of FORD MOTOR CO.
  3. Install each rivet, using a suitable hydraulic or mechanical press and riveting fixture and applying the force specified.
    4. CAUTION: Place the differential side bearing cups on the differential side bearings after pressing the bearings on the case. This will prevent bearing damage during the remaining assembly process.
    Fig 4: Pressing Differential Side Bearings On Differential Case Halves
    G01551113Courtesy of FORD MOTOR CO.
  4. Press the differential side bearings on the differential case halves, and place the bearing cups on the bearings.
    5. NOTE: Lightly lubricate all of the mating surfaces with clean axle lubricant. This will aid in assembly and provide initial lubrication.
  5. On the conventional differential, install the gear assembly.
    1. Position the thrust washer and the differential side gear into the case half.
    2. Position the differential cross shaft with the pinion mates and the thrust washers into the case half.
    3. Position the differential side gear and thrust washer on the differential pinion mates.
      Fig 5: Installing Gear Assembly On Conventional Differential
      G01551114Courtesy of FORD MOTOR CO.
    6. CAUTION: Align the match marks.
    Fig 6: Assembling Differential Case Halves On Conventional Differential
    G01551115Courtesy of FORD MOTOR CO.
  6. On the conventional differential, assemble the differential case halves.
    7. CAUTION: Do not damage the differential ring gear and pinion.
    Fig 7: Positioning Differential Subassembly Into Carrier Using Special Tool
    G01551116Courtesy of FORD MOTOR CO.
  7. Using the special tool, carefully position the differential subassembly into the carrier.
    8. CAUTION: The bearing cups must seat on the differential side bearings.
    CAUTION: Align the match marks.
  8. Install the differential bearing caps.
    1. Position the bearing cap onto the leg.
      2. CAUTION: The bolt threads must be clean.
    2. Apply Threadlock 262 to the bolt threads, and install the bolts.
      • Tighten the bolts enough to eliminate visible space between the bearing cap and leg. Do not tighten the bolts to the appropriate torque at this time.
        Fig 8: Positioning Bearing Cap Onto Leg
        G01551117Courtesy of FORD MOTOR CO.
    9. CAUTION: Align the differential assembly within the bearing bores before applying preload or damage to the bearings will result.
  9. Install the differential bearing adjusting rings.
    • Tighten both adjusting rings until there is zero end play, and some backlash between the differential ring gear and pinion. Make sure the adjusting ring tooth aligns so that installation of the adjusting ring lock is possible.
      Fig 9: Installing Differential Bearing Adjusting Rings
      G01551118Courtesy of FORD MOTOR CO.
  10. Set the backlash at zero.
      NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring lock is possible.
      Fig 10: Setting Backlash Using Dial Indicator
      G01551119Courtesy of FORD MOTOR CO.
    • Loosen the adjusting ring on the tooth side of the differential ring gear one tooth, and tighten the opposite adjusting ring one tooth. Repeat this process until backlash is at zero.
  11. Set the backlash and the bearing preload to specifications.
    • With a new matched set installed, set the backlash to the specification etched in the differential ring gear.
    • With the original matched set installed, set the backlash to the specification recorded prior to disassembly.
      • NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring lock is possible.
      Fig 11: Setting Backlash And Bearing Preload Using Dial Indicator
      G01551120Courtesy of FORD MOTOR CO.
    • Tighten the adjusting ring on the tooth side of the differential ring gear until backlash is within specifications.
  12. Check the differential ring gear and pinion backlash in four equally spaced positions around the differential ring gear.
    • The acceptable backlash tolerance is +/- 0.0508 mm (0.002 inch) from the backlash etched in the differential ring gear.
    • If the backlash tolerance varies more than 0.080 mm (0.003 inch) between the four positions, remove the differential and determine the cause.
      Fig 12: Checking Differential Ring Gear And Pinion Backlash Using Dial Indicator
      G01551121Courtesy of FORD MOTOR CO.
  13. Tighten the bolts.
    • Check the differential ring gear and pinion backlash, as described in the previous step, after tightening the bolts.
      Fig 13: Tightening Bolts
      G01551122Courtesy of FORD MOTOR CO.
  14. Install the adjusting ring locks.
    Fig 14: Installing Adjusting Ring Locks
    G01551123Courtesy of FORD MOTOR CO.
  15. Install the rear anti-lock brake sensor.
    Fig 15: Installing Rear Anti-Lock Brake Sensor
    G01551124Courtesy of FORD MOTOR CO.
  16. Install the carrier. Refer to Differential Carrier .
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