Differential Case: Installation

WARNING: This page is about a different car, the 2008 Ford Pickup and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Install the outboard spacers in the side from which they were removed.

Fig 1: Outboard Spacers

Courtesy of FORD MOTOR CO.

NOTE: Remove all nicks, burrs and dirt from the differential case hubs to allow the Dummy Bearing Set to rotate freely.

Place the Dummy Bearing Set on the differential case hubs and position the assembly into the differential housing.

Fig 2: Identifying Special Tools (205-D048) On Differential Case Hubs

Courtesy of FORD MOTOR CO.

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.

Mount the Dummy Bearing Set and Dial Indicator with Holding Fixture as shown.

Fig 3: Mounting Special Tools (205-D048, 100-002)

Courtesy of FORD MOTOR CO.

NOTE: Repeat this and the following step until the same readings appear on the Dial Indicator each time. This is the total differential bearing shim thickness necessary, less preload. The final calculation occurs later during assembly.

Force the differential case as far as possible toward the Dial Indicator. With force applied, set the indicator at 0. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.

Fig 4: Checking Differential Case End Play

Courtesy of FORD MOTOR CO.

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.

NOTE: Apply threadlock to the 2 new bolts.

Start 2 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: Identifying Bolts In Differential Case Flange, Anti-Lock Sensor Ring & Differential Ring Gear

Courtesy of FORD MOTOR CO.

Press the anti-lock speed sensor 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

Courtesy of FORD MOTOR CO.

NOTE: Apply threadlock to the remaining new bolt threads.

Draw up the 12 new ring gear bolts alternately and evenly.
- Tighten to 298 Nm (220 lb-ft).

Fig 7: Ring Gear Bolts (4 Remaining)

Courtesy of FORD MOTOR CO.

Place the differential assembly with the Dummy Bearing Set in the differential housing.

Fig 8: Differential Assembly & Special Tools (205-D048) In Differential Housing

Courtesy of FORD MOTOR CO.

Install the Dial Indicator 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: Installing Special Tools (205-D048, 100-002, 308-021)

Courtesy of FORD MOTOR CO.

NOTE: Repeat this and the following step until the same readings appear on the Dial 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.

Force the differential case and ring gear away from the drive pinion. With force applied, set the Dial Indicator to 0.

Fig 10: Zeroing Dial Indicator

Courtesy of FORD MOTOR CO.

Force the differential ring gear into mesh with the pinion to obtain an Dial Indicator reading. Record this measurement.

Fig 11: Checking Backlash

Courtesy of FORD MOTOR CO.

Remove the differential case from the differential housing.
Remove the Dummy Bearing Set from the differential case.
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.
Using the Differential Carrier Bearing Installer, install the new differential bearing on the differential ring gear side of the differential case.

Fig 12: Identifying Special Tool (205-D044) For Differential Bearing Installation

Courtesy of FORD MOTOR CO.

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.
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: Using Special Tools (205-432, 205-D044) To Install Differential Bearing Onto Hub

Courtesy of FORD MOTOR CO.

Assemble the differential bearing cups to the differential bearings.

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.

Using the Differential Carrier Spreader and Dial Indicator with Holding Fixture, spread the differential housing to specifications and position the differential assembly.
- Use a rawhide hammer to seat the differential in the differential housing.

Fig 14: Spreading Differential Housing Using Differential Carrier Spreader & Dial Indicator Gauge With Holding Fixture

Courtesy of FORD MOTOR CO.

NOTE: Match the mating letters as noted during disassembly.

Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
- Tighten to 108 Nm (80 lb-ft).

Fig 15: Locating Differential Bearing Caps

Courtesy of FORD MOTOR CO.

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 article.
Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA article.

NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.

Apply a continuous bead of sealant of the specified thickness to the differential housing cover.

Fig 16: Applying Continuous Bead Of Sealant Of Specified Thickness To Differential Housing Cover

Courtesy of FORD MOTOR CO.

Place 2 bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover on the differential housing.
Install the 8 remaining bolts. Tighten the bolts alternately and evenly.
- Tighten to 45 Nm (33 lb-ft).
- If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.
Fill the axle to specification.