Differential Carrier: Installation

WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 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: Locating 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 And 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: Aligning Letters On Differential Housing
  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 And Pinion Backlash
Courtesy of FORD MOTOR CO.
Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .

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

Fig 5: Locating Sealant Applying Areas On Differential Housing Cover

Courtesy of FORD MOTOR CO.

Apply a continuous bead of sealant to the differential housing cover as shown in illustration.
Install the differential housing cover and the 10 bolts. Tighten the bolts.
- Tighten alternately and evenly to 45 Nm (33 lb-ft).

NOTE: If possible, allow an hour before filling with lubricant to make sure the silicone sealant has correctly cured.

Fill the axle with the specified type and amount of lubricant.