Differential Carrier: 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 spacer in its original location.

Fig 1: Outboard Spacers

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 Dial Indicator Gauge with Holding Fixture and Differential Carrier Spreader, spread the differential housing to the specification.
- Use a rawhide hammer to seat the differential into the differential housing pocket.

Fig 2: 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 3: Locating Differential Bearing Caps

Courtesy of FORD MOTOR CO.

Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the differential ring gear and pinion backlash at 3 equally spaced points.

Fig 4: Measuring Differential Ring Gear & Pinion Backlash Using Special Tools (100-002, 308-021)

Courtesy of FORD MOTOR CO.

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 5: Applying A 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.