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.

Position the differential assembly in the axle housing.

Fig 1: Positioning Differential Assembly In Axle Housing

Courtesy of FORD MOTOR CO.

Install the original removed differential bearing shims in their original positions.

Fig 2: Identifying Differential Bearing Shims

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Using the Differential Shim Installer, fully seat the differential bearing shims.

Fig 3: Installing Differential Bearing Shim Using Special Tool (205-228)

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Install the 2 differential bearing caps and the 4 differential bearing cap bolts.
- Tighten to 119 Nm (88 lb-ft).

Fig 4: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts

Courtesy of FORD MOTOR CO.

Rotate the differential assembly to make sure it rotates freely.

Fig 5: Rotating Differential Assembly

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Using the Dial Indicator with Brackets and the Clutch Housing Gauge, measure the ring and pinion backlash.

Fig 6: Measuring Ring Gear Backlash Using Special Tools (100-002, 308-021)

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Install the axle shafts. For additional information, refer to Axle Shaft .

NOTE: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant.

Clean the gasket mating surface of the differential housing and the differential housing cover.
Apply a continuous bead of silicone sealant to the differential housing cover.

Fig 7: Proper Application Of Sealant To Differential Housing Cover

Courtesy of FORD MOTOR CO.

NOTE: The differential housing cover must be installed within 15 minutes of the application of silicone or new the silicone must be removed and reapplied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has properly cured.

Install the differential housing cover and the 12 differential housing cover bolts.
- For a stamped steel cover, tighten to 45 Nm (33 lb-ft).
- For a cast aluminum cover, tighten to 32 Nm (24 lb-ft).

Fig 8: Locating Differential Housing Cover Bolts

Courtesy of FORD MOTOR CO.

NOTE: For Traction-Lok® axles, first fill the axle with 118 ml (4 oz.) of friction modifier or damage to the axle may occur.

Fill the axle to the level shown with axle lubricant and install the filler plug.
- Tighten to 30 Nm (22 lb-ft).

Fig 9: Checking Axle Lubricant Fill Level

Courtesy of FORD MOTOR CO.

Install the axle shafts. For additional information, refer to Axle Shaft .