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Differential Case: Installation

WARNING: This page is about a different car, the 2011 Ford Pickup and 2011 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the outboard spacers in the side from which they were removed.
    Fig 1: Installing Outboard Spacer
    G06594702Courtesy of FORD MOTOR CO.
  2. Place the Dummy Bearing Set on the differential case hubs and position the assembly into the differential housing.
    NOTE: Remove all nicks, burrs and dirt from the differential case hubs to allow the Dummy Bearing Set to rotate freely.
    Fig 2: Positioning Assembly Into Differential Housing
    G06776616Courtesy of FORD MOTOR CO.
  3. Mount the Dummy Bearing Set and Dial Indicator Gauge with Holding Fixture as shown in illustration.
    NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.
    Fig 3: Identifying Dummy Bearing Set And Dial Indicator Gauge
    G06776617Courtesy of FORD MOTOR CO.
  4. Force the differential case as far as possible toward the Dial Indicator Gauge. With force applied, set the Dial Indicator Gauge at 0. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
    NOTE: Repeat this and the following step until the same readings appear on the Dial Indicator Gauge each time. This is the total differential bearing shim thickness necessary, less preload. The final calculation occurs later during assembly.
    • Contact Spicer Service at 1-800-826-4357 for assistance with differential case runout results and further diagnosis.
    Fig 4: Measuring Total Differential Case End Play
    G06776618Courtesy of FORD MOTOR CO.
  5. After making sure the reading is repeatable, remove the differential case from the differential housing. Do not remove the Dummy Bearing Set from the differential case at this time.
  6. Start 2 new bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and differential case align.
    Fig 5: Locating Differential Case Flange Bolts
    G06776619Courtesy of FORD MOTOR CO.
  7. Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
    Fig 6: Pressing Anti-Lock Speed Sensor Ring
    G06776620Courtesy of FORD MOTOR CO.
  8. Draw up the 12 new ring gear bolts alternately and evenly.
    • Tighten to 298 Nm (220 lb-ft).
    Fig 7: Identifying Ring Gear Bolts
    G06776612Courtesy of FORD MOTOR CO.
  9. Place the differential assembly with the Dummy Bearing Set in the differential housing.
    Fig 8: Removing Differential Case Using Required Tool
    G06776622Courtesy of FORD MOTOR CO.
  10. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge. Locate the tip of the Clutch Housing Gauge on the flat surface of one of the bolts.
    Fig 9: Identifying Dial Indicator Gauge With Holding Fixture And Clutch Housing Gauge
    G06776623Courtesy of FORD MOTOR CO.
  11. Force the differential case and ring gear away from the drive pinion. With force applied, set the Dial Indicator Gauge to 0.
    NOTE: Repeat this and the following step until the same readings appear on the Dial Indicator Gauge each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.
    Fig 10: Measuring Differential Case End Play Using Required Tool (Away From Drive Pinion)
    G06776624Courtesy of FORD MOTOR CO.
  12. Force the differential ring gear into mesh with the pinion to obtain a Dial Indicator Gauge reading. Record this measurement.
    Fig 11: Measuring Differential Case End Play Using Required Tool (Toward Drive Pinion)
    G06776625Courtesy of FORD MOTOR CO.
  13. Remove the differential case from the differential housing.
  14. Remove the Dummy Bearing Set from the differential case.
  15. Place a shim of the thickness determined by the end play between the differential case and the ring gear/pinion on the ring gear side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
  16. Using the Differential Carrier Bearing Installer, install the new differential bearing on the differential ring gear side of the differential case.
    Fig 12: Installing Differential Bearing On Differential Case Using Required Tool
    G06776626Courtesy of FORD MOTOR CO.
  17. Determine the correct shim thickness and place the shim on the differential case hub on the drive pinion side.
    • To determine the correct shim thickness, first subtract the thickness of the ring gear side differential case hub shim from the total differential case end play reading recorded earlier. Then, add 0.25 mm (0.010 in) to this amount. This result is the correct thickness of shim to place on the pinion side differential hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
  18. Using the Differential Carrier Bearing Installer, install the differential bearing.
    1. Place the Differential Carrier Bearing Step Plate on the differential bearing to protect it during the installation of the opposite bearing.
    2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.
    Fig 13: Installing Differential Bearing Using Bearing Insataller
    G06776627Courtesy of FORD MOTOR CO.
  19. Assemble the differential bearing cups to the differential bearings.
  20. Using the Differential Carrier Spreader and Dial Indicator Gauge with Holding Fixture, spread the differential housing to specifications and position the differential assembly.
    NOTE: Do not spread the differential housing more than specified or damage to the housing may occur.
    NOTE: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly or damage to the component may occur.
    • Use a rawhide hammer to seat the differential in the differential housing.
    Fig 14: Spreading Differential Housing Using Differential Carrier Spreader
    G06776608Courtesy of FORD MOTOR CO.
  21. Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
    NOTE: Match the mating letters as noted during disassembly.
    • Tighten to 108 Nm (80 lb-ft).
    Fig 15: Locating Letters On Differential Bearings
    G06776629Courtesy of FORD MOTOR CO.
  22. Carry out the Tooth Contact Pattern Check to verify that the final pinion position is correct. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
  23. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
  24. Apply a continuous bead of sealant to the differential housing cover as shown in illustration.
    NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.
    Fig 16: Locating Sealant Applying Area Of Differential Housing Cover
    G06776630Courtesy of FORD MOTOR CO.
  25. Install the differential housing cover and the 10 bolts.
    • Tighten alternately and evenly to 45 Nm (33 lb-ft).
    Fig 17: Locating Differential Housing Cover Bolts
    G06776631Courtesy of FORD MOTOR CO.
  26. Fill the axle with the specified type and amount of lubricant.
    NOTE: If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.
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