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Home >> Ford >> 2002 >> Taurus SES, 3.0 S >> Repair and Diagnosis >> External Pages >> Different car >> Section 397 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> General Procedures >> Differential Case and Pinion Set Up >> Ring Gear and Pinion Backlash

Ring Gear and Pinion Backlash

WARNING: This page is about a different car, the 2003 Ford Pickup and 2003 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 Spacers In Side
    G01550816Courtesy of FORD MOTOR CO.
  2. Place the differential assembly with the special tool in the differential housing.
    Fig 2: Placing Differential Assembly With Special Tool In Differential Housing
    G01550817Courtesy of FORD MOTOR CO.
  3. Install the special tools. Locate the tip of the Clutch Housing Gauge on a flat surface of one of the bolts.
    Fig 3: Installing Special Tools And Locating Tip Of Clutch Housing Gauge On A Flat Surface Of One Of Bolts
    G01550818Courtesy of FORD MOTOR CO.
    4. NOTE: Repeat this step and the following step until the same reading appears on the indicator 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 4: Forcing Differential Case (Differential Ring Gear) Away From Drive Pinion
    G01550819Courtesy of FORD MOTOR CO.
  4. Force the differential case (differential ring gear) away from the drive pinion. With force still applied, set the indicator at 0.
  5. Force the differential ring gear into mesh with the pinion, to obtain an indicator reading. Record the reading.
    Fig 5: Forcing Differential Ring Gear Into Mesh With Pinion
    G01550820Courtesy of FORD MOTOR CO.
  6. Remove the special tools and the differential case from the differential housing.
  7. Remove the Master Bearings from the differential case.
  8. Place one shim, of the necessary thickness as determined from the previous measurement, on the differential 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.
  9. Using the special tool, install the differential bearing on the differential ring gear side of the differential case.
    Fig 6: Installing Differential Bearing On Differential Ring Gear Side Of Differential Case Using Special Tool
    G01550821Courtesy of FORD MOTOR CO.
  10. Determine the correct shim thickness, and place the shim on differential case hub on the drive pinion side.
    • To determine the correct shim thickness, first subtract the reading of the previous measurement from the total differential case end play reading obtained under Differential Case End Play Check in this section. Then, add 0.25 mm (0.010 in) to this amount. This is the correct thickness shim to place on the hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
  11. Using the special tools, install the differential bearing.
    1. Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
    2. Using the special tool, drive the differential bearing onto the hub.
      Fig 7: Driving Differential Bearing Onto Hub Using Special Tool
      G01550823Courtesy of FORD MOTOR CO.
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