Differential Case: Installation

All vehicles 

1. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case.
   Fig 1: Pressing Ring Gear

   Courtesy of FORD MOTOR CO.
2. Install the ring gear bolts.
   • Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts.
     Fig 2: Installing Ring Gear Bolts

     Courtesy 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.
     Fig 3: Installing Shim On Left Side

     Courtesy of FORD MOTOR CO.
CAUTION: 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.
Fig 4: Installing Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
4. Install the left bearing cap, and loosely install the bearing cap bolts.
5. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
   Fig 5: Installing Progressively Larger Shims On Right Side

   Courtesy of FORD MOTOR CO.
6. Install the right side bearing cap, and tighten the bolts.
   Fig 6: Installing Right Side Bearing Cap, And Tightening Bolts

   Courtesy of FORD MOTOR CO.
7. Rotate the differential case to make sure it rotates freely.
   Fig 7: Rotating Differential Case

   Courtesy of FORD MOTOR CO.

   Measuring backlash 

8. Using the special tool, measure ring gear backlash.
   • 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 .
   • 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.
     Fig 8: Measuring Ring Gear Backlash

     Courtesy of FORD MOTOR CO.

   Zero backlash 

9. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step  8.
   Fig 9: Specification Chart (1 Of 2)

   Courtesy of FORD MOTOR CO.
   Fig 10: Specification Chart (2 Of 2)

   Courtesy of FORD MOTOR CO.

   Backlash not within specification 

10. To increase or decrease backlash, remove the 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.
      Fig 11: Installing Thicker Shim And Thinner Shim

      Courtesy of FORD MOTOR CO.
11. Install the bearing caps and bearing cap bolts.
    Fig 12: Installing Bearing Caps And Bearing Cap Bolts

    Courtesy of FORD MOTOR CO.
12. Rotate the differential several times to make sure the differential bearings are properly seated.
    Fig 13: Rotating Differential

    Courtesy of FORD MOTOR CO.
13. Using the special tool, recheck the backlash.
    • If backlash is within specification, go to Backlash within specification in this procedure. If not, repeat Step  8.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
      Fig 14: Rechecking Backlash

      Courtesy of FORD MOTOR CO.

    Backlash within specification 

14. Remove the bearing caps and bolts.
    • To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
    • Using the special tool, ensure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 15: Removing Bearing Caps And Bolts

      Courtesy of FORD MOTOR CO.
15. Install the bearing caps and bearing cap bolts.
    Fig 16: Installing Bearing Caps And Bearing Cap Bolts

    Courtesy of FORD MOTOR CO.
16. Using the special tool, verify the backlash.
    • The specification shown is the full allowable range. For the preferred range, refer to SPECIFICATIONS .
    • For further adjustments, refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
      Fig 17: Verifying Backlash

      Courtesy of FORD MOTOR CO.
17. Install the axle shafts; Refer to Axle Assembly .
CAUTION: 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 sealant to the differential housing cover.
    • Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford Specifications ESB-M4G92-A.
      Fig 18: Applying Continuous Bead Of Sealant To Differential Housing Cover

      Courtesy of FORD MOTOR CO.
20. Install the driveshaft. Refer to DRIVESHAFT .