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Home >> Ford >> 2002 >> Excursion 6.8 S, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 316 (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 2002 Ford F550 Super Duty and 2002 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: Aligning Tab On Sensor Ring
    G02172957Courtesy 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
    G02172958Courtesy 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
    G02172959Courtesy 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 (4222) on the differential side bearings after pressing the bearings on the case. This will prevent bearing damage during the remaining assembly process.
    Fig 4: Installing Differential Side Bearings
    G02172960Courtesy 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.
    Fig 5: Positioning Differential Side Gear
    G02172961Courtesy of FORD MOTOR CO.
  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.
    6. CAUTION: Align the match marks.
    Fig 6: Aligning Match Marks
    G02172962Courtesy 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
    G02172963Courtesy 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.
    Fig 8: Aligning Match Marks
    G02172964Courtesy of FORD MOTOR CO.
  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 E2FZ-19554-B or equivalent meeting Ford specification WSK-M2G351-A6 to the bolt threads, and install the bolts.
      1. 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.
    9. CAUTION: Align the differential assembly within the bearing bores before applying preload or damage to the bearings will result.
    Fig 9: Installing Differential Bearing Caps
    G02172965Courtesy of FORD MOTOR CO.
  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.
  10. Set the backlash at zero.
      NOTE: The adjusting ring tooth must always align so that installation of the adjusting ring lock is possible.
    • 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.
    Fig 10: Checking Backlash
    G02172966Courtesy of FORD MOTOR CO.
  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.
    • Tighten the adjusting ring on the tooth side of the differential ring gear until backlash is within specifications.
    Fig 11: Setting Backlash And Bearing Preload To Specifications
    G02172967Courtesy of FORD MOTOR CO.
  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
    G02172968Courtesy 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
    G02172969Courtesy of FORD MOTOR CO.
  14. Install the adjusting ring locks.
    Fig 14: Installing Adjusting Ring Locks
    G02172970Courtesy of FORD MOTOR CO.
  15. Install the rear anti-lock brake sensor.
    Fig 15: Installing Rear Anti-Lock Brake Sensor
    G02172971Courtesy of FORD MOTOR CO.
  16. Install the carrier. For additional information, refer to DIFFERENTIAL CARRIER .
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