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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2127 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- F250-F350 Super Duty) >> In-Vehicle Servicing >> Differential Case >> Installation

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.

All vehicles 

    NOTE: If removed, press the new speed sensor ring on with the differential ring gear.
  1. Install the differential ring gear.
    1. Place the differential ring gear on the differential case.
    2. Hand start 3 new ring gear bolts to align the ring gear and differential case.
    3. Place the differential assembly on the press bed.
    4. Press the ring gear into place with the Differential Carrier Bearing Step Plate and a suitable press.
    2. Fig 1: Pressing Ring Gear Into Place With Differential Carrier Bearing Step Plate & A Suitable Press
    GF0049196Courtesy of FORD MOTOR CO.
  2. Install the remaining 9 new ring gear bolts.
    • Tighten to 150 Nm (111 lb-ft).
    3. Fig 2: Identifying Ring Gear Bolts
    G03883503Courtesy of FORD MOTOR CO.
  3. With the pinion depth set and the pinion installed, place the differential case in the rear axle housing.
    • Install a shim on the left side as shown in the illustration.
    4. Fig 3: Identifying Differential Bearing Shim On Left Side
    GF0003162Courtesy of FORD MOTOR CO.
    NOTE: The bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left bearing is seated.
  4. Install the left bearing cap and loosely install the 2 bearing cap bolts.
    5. Fig 4: Left Bearing Cap & Bolts
    GF0006501Courtesy of FORD MOTOR CO.
  5. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
    6. Fig 5: Installing Right Side Shim
    GF0006502Courtesy of FORD MOTOR CO.
  6. Install the right side bearing cap and 2 bolts. Tighten the 4 bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
    7. Fig 6: Bearing Cap Bolt
    GF0006503Courtesy of FORD MOTOR CO.
  7. Rotate the differential case to make sure it rotates freely.
    8. Fig 7: Rotating Differential Case
    GF0006492Courtesy of FORD MOTOR CO.

    Measuring backlash 

  8. Using the Dial Indicator Gauge with Holding Fixture, measure ring gear backlash.
    • If a zero backlash condition occurs, go to Zero backlash in this procedure.
    • If the backlash is not within specification, go to Backlash not within specification in this procedure.
    • If the backlash is within specification, go to Backlash within specification in this procedure. The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
    9. Fig 8: Measuring Ring Gear Backlash (With Specifications)
    GF0006504Courtesy of FORD MOTOR CO.

    Zero backlash 

  9. If a zero backlash condition occurs, add a 0.50 mm (0.020 in) shim to the RH side and subtract 0.50 mm (0.020 in) from the LH side to allow backlash indication. Check backlash. Repeat Step 8.
    Backlash Change Required Thickness Change Required
    mm Inch mm Inch
    0.025 0.001 0.050 0.002
    0.050 0.002 0.050 0.002
    0.076 0.003 0.101 0.004
    0.101 0.004 0.152 0.006
    0.127 0.005 0.152 0.006
    0.152 0.006 0.203 0.008
    0.177 0.007 0.254 0.010
    0.203 0.008 0.254 0.010
    0.228 0.009 0.304 0.012
    0.254 0.010 0.355 0.014
    0.279 0.011 0.355 0.014
    0.304 0.012 0.406 0.016
    0.330 0.013 0.457 0.018
    0.335 0.014 0.457 0.018
    0.381 0.015 0.508 0.020

    10. Backlash not within specification 

  10. To increase or decrease backlash, remove the 4 bolts and 2 bearing caps and install a thicker shim and a thinner shim as shown.
    • If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
    11. Fig 9: Bearing Caps
    GF0006505Courtesy of FORD MOTOR CO.
  11. Install the 2 bearing caps and 4 bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
    12. Fig 10: Bearing Cap Bolt
    GF0006503Courtesy of FORD MOTOR CO.
  12. Rotate the differential several times to make sure the differential bearings are correctly seated.
    13. Fig 11: Rotating Differential Case
    GF0006492Courtesy of FORD MOTOR CO.
  13. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the backlash.
    • If backlash is within specification, go to Backlash within specification in this procedure. If not, repeat Step 8.
    14. Fig 12: Measuring Ring Gear Backlash Using Special Tools (100-002, 308-021)
    G03884451Courtesy of FORD MOTOR CO.

    Backlash within specification 

  14. Remove the 2 bearing caps and 4 bolts.
    • To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
    • Using the Differential Shim Installer, make sure the differential bearing shims are fully seated and the assembly turns freely.
    15. Fig 13: Installing Differential Bearing Shim Using Special Tool (205-228)
    G03904436Courtesy of FORD MOTOR CO.
  15. Install the 2 bearing caps and 4 bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
    16. Fig 14: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  16. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, verify the backlash.
    17. Fig 15: Measuring Ring Gear Backlash Using Special Tools (100-002, 308-021)
    G03884451Courtesy of FORD MOTOR CO.
  17. Install the axle shafts. For additional information, refer to Axle Shaft .
    18. NOTE: Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
  18. Clean the gasket mating surface of the rear axle and the differential housing cover.
  19. Apply a new, continuous bead of silicone sealant to the differential housing cover.
    20. Fig 16: Proper Application Of Sealant To Differential Housing Cover
    GF0003119Courtesy of FORD MOTOR CO.
    NOTE: The differential cover must be installed within 15 minutes of application of the silicone or new sealant must be applied. If possible, allow an hour before filling with lubricant to make sure the sealant has properly cured.
  20. Install the differential cover and the 12 differential housing cover bolts.
    • For stamped steel covers, tighten to 45 Nm (33 lb-ft).
    • For cast aluminum covers, tighten to 32 Nm (24 lb-ft).
    21. NOTE: For Traction-Lok® axles, first fill the axle with 118 ml (4 oz.) of friction modifier.
    NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.
  21. Fill the axle to the level shown with axle lubricant and install the filler plug.
    • Tighten to 30 Nm (22 lb-ft).
    22. Fig 17: Checking Axle Lubricant Fill Level
    G03884460Courtesy of FORD MOTOR CO.
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