Removal And Installation: Removal: Installation

All Vehicles 

1. Position the differential assembly in the axle housing.
   Fig 1: Identifying Differential Assembly In Axle Housing

   Courtesy of FORD MOTOR CO.
2. Install the original differential bearing shim on the LH side.
   Fig 2: Locating Differential Bearing Shims

   Courtesy of FORD MOTOR CO.

   ELD equipped vehicles 

3. Push the ELD coil electrical connector through the differential case and connect the connector to the new adapter.
   Fig 3: Locating Connector Adapter

   Courtesy of FORD MOTOR CO.
4. Seat the connector adapter into the differential housing and install the bolt. Connect the electrical connector.
   • Tighten to 15 Nm (133 lb-in).
   Fig 4: Locating Bolt And Electronic Locking Differential Connector

   Courtesy of FORD MOTOR CO.

   All vehicles 

5. Install the original differential bearing shim on the RH side.
   Fig 5: Installing Differential Bearing Shim On RH Side

   Courtesy of FORD MOTOR CO.
6. Using the Differential Shim Installer, fully seat the differential bearing shims.
   Fig 6: Tapping Differential Bearing Shims

   Courtesy of FORD MOTOR CO.
7. Install the 2 differential bearing caps and the 4 differential bearing cap bolts.
   • Tighten to 118 Nm (87 lb-ft).
   Fig 7: Locating Differential Bearing Cap Bolts

   Courtesy of FORD MOTOR CO.
8. Rotate the differential assembly to make sure it rotates freely.
   Fig 8: Rotating Differential Assembly

   Courtesy of FORD MOTOR CO.
9. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the ring and pinion backlash.
   Fig 9: Measuring Ring Gear Backlash Using Special Tools

   Courtesy of FORD MOTOR CO.
10. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - FORD .
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. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
11. Clean the gasket mating surface of the differential housing and the differential housing cover.
12. Apply a continuous bead of silicone to the differential housing cover as shown in illustration.
    Fig 10: Identifying Sealant Applying Area 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 the silicone must be removed and reapplied. If possible, allow one hour before filling with lubricant to make sure the silicone has properly cured.
Fig 11: Locating Differential Housing Cover Bolts
Courtesy of FORD MOTOR CO.
13. Install the differential housing cover and the 12 differential housing cover bolts.
    • For a stamped steel cover, tighten alternately and evenly to 45 Nm (33 lb-ft).
    • For a cast aluminium cover, tighten alternately and evenly to 32 Nm (24 lb-ft).
14. Remove the fill plug, fill the axle to the level shown in illustration with axle lubricant and install the filler plug.
    • Tighten to 30 Nm (22 lb-ft).

Fig 12: Identifying Axle Lubricant Fill Level

Courtesy of FORD MOTOR CO.