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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2613 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- F250-F350 Super Duty) >> In-Vehicle Repair >> Differential Case >> Installation

Differential Case: Installation

WARNING: This page is about a different car, the 2011 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles 

  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.
    Fig 1: Installing Differential Ring Gear Using Differential Carrier Bearing Step Plate
    G07478457Courtesy of FORD MOTOR CO.
  2. Install the remaining 9 new ring gear bolts.

    1

    • Tighten to 63 Nm (46 lb-ft) and then tighten an additional 60 degrees.
    Fig 2: Locating Ring Gear Bolt
    G07478458Courtesy 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: View Of Shim Installation Position On Differential Case
    G07478459Courtesy of FORD MOTOR CO.
  4. Install the left bearing cap and loosely install the 2 bearing cap bolts.
    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.
    Fig 4: Locating Bearing Cap Bolts
    G07478460Courtesy of FORD MOTOR CO.

    ELD equipped vehicles 

  5. Push the ELD coil electrical connector through the differential case and connect the connector to the new adapter.
    Fig 5: Locating ELD Coil Electrical Connector
    G07478461Courtesy of FORD MOTOR CO.
  6. Seat the connector adapter into the differential housing and Install the bolt. Connect the electrical connector.
    • Tighten to 15 Nm (133 In lb).
    Fig 6: Locating Connector Adapter Bolt
    G07478462Courtesy of FORD MOTOR CO.

    All vehicles 

  7. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
    Fig 7: Locating Larger Shim On Differential Housing
    G07478463Courtesy of FORD MOTOR CO.
  8. Install the right side bearing cap and 2 bolts. Tighten the 4 bearing cap bolts.
    • Tighten to 118 Nm (87 lb-ft).
    Fig 8: Locating Differential Bearing Cap Bolts
    G07478464Courtesy of FORD MOTOR CO.
  9. Rotate the differential case to make sure it rotates freely.
    Fig 9: Rotating Differential Case
    G07478465Courtesy of FORD MOTOR CO.

    Measuring backlash 

  10. 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 .
    Fig 10: Measuring Ring Gear Backlash Using Special Tools
    G07478466Courtesy of FORD MOTOR CO.

    Zero backlash 

  11. 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.
    RING GEAR BACKLASH AND THICKNESS SPECIFICATIONS

    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

    Backlash not within specification 

  12. To increase or decrease backlash, remove the 4 bolts and 2 bearing caps and install a thicker shim and a thinner shim as shown in illustration.
    • 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: Locating Differential Bearing Caps
    G07478467Courtesy of FORD MOTOR CO.
  13. Install the 2 bearing caps and 4 bearing cap bolts.
    • Tighten to 118 Nm (87 lb-ft).
    Fig 12: Locating Differential Bearing Cap Bolts
    G07478468Courtesy of FORD MOTOR CO.
  14. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 13: View Of Differential Case
    G07478469Courtesy of FORD MOTOR CO.
  15. 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.
    Fig 14: Measuring Ring Gear Backlash Using Special Tools
    G07478470Courtesy of FORD MOTOR CO.

    Backlash within specification 

  16. 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.
    Fig 15: Installing Differential Shim Using Differential Shim Installer
    G07478471Courtesy of FORD MOTOR CO.

    All vehicles 

  17. Install the 2 bearing caps and 4 bearing cap bolts.
    • Tighten to 118 Nm (87 lb-ft).
    Fig 16: Locating Differential Bearing Cap Bolts
    G07478472Courtesy of FORD MOTOR CO.
  18. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, verify the backlash.
    Fig 17: Measuring Ring Gear Backlash Using Special Tools
    G07478473Courtesy of FORD MOTOR CO.
  19. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - FORD .
  20. Clean the gasket mating surface of the rear axle and the differential housing cover.
    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. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
  21. Apply a new, continuous bead of silicone to the differential housing cover as shown in illustration.
    Fig 18: Locating Silicone Applying Area Of Differential Housing Cover
    G07478474Courtesy of FORD MOTOR CO.
  22. Install the differential cover and the 12 differential housing cover bolts.
    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.
    • For stamped steel covers, tighten alternately and evenly to 45 Nm (33 lb-ft).
    • For cast aluminum covers, tighten alternately and evenly to 32 Nm (24 lb-ft).
  23. Remove the filler plug, fill the axle to the level shown with axle lubricant and install the filler plug.
    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.
    • Tighten to 30 Nm (22 lb-ft).
    Fig 19: Identifying Axle Lubricant Filling Level
    G07478475Courtesy of FORD MOTOR CO.
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