Differential Carrier: Installation

WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Position the differential assembly in the axle housing.

Fig 1: Positioning Differential Assembly In Axle Housing
Courtesy of FORD MOTOR CO.
Install the original removed differential bearing shims in their original positions.

Fig 2: Locating Differential Bearing Shims
Courtesy of FORD MOTOR CO.
Using the Differential Shim Installer, fully seat the differential bearing shims.

Fig 3: Installing Differential Bearing Shims
Courtesy of FORD MOTOR CO.
Install the 2 differential bearing caps and the 4 differential bearing cap bolts.
- Tighten to 119 Nm (88 lb-ft).
  
  Fig 4: Locating Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Rotate the differential assembly to make sure it rotates freely.

Fig 5: Rotating Differential Assembly
Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the ring and pinion backlash.

Fig 6: Measuring Ring Gear Backlash Using Special Tools
Courtesy of FORD MOTOR CO.
Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - FORD .

NOTE: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before applying the new silicone. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the differential housing and the differential housing cover.
Apply a continuous bead of silicone to the differential housing cover as shown in illustration.

Fig 7: Locating Differential Housing Cover Silicone Applying Areas
Courtesy of FORD MOTOR CO.

NOTE: The differential housing cover must be installed within 15 minutes of the application of silicone or the silicone must be removed and reapplied. If possible, allow one hour before filling with lubricant to make sure the silicone has properly cured.

Install the differential housing cover and the 12 differential housing cover bolts.
- For a stamped steel cover, tighten alternately and evenly to 45 Nm (33 lb-ft).
- For a cast aluminum cover, tighten alternately and evenly to 32 Nm (24 lb-ft).
  
  Fig 8: Locating Differential Housing Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: For Traction-Lok® axles, first fill the axle with 118 ml (4 oz) of friction modifier or damage to the axle may occur.

Remove the fill plug, fill the axle to the level shown in illustration with axle lubricant and install the filler plug.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 9: Identifying Axle Lubricant Fill Level
  Courtesy of FORD MOTOR CO.