Differential Case: Installation

All vehicles 

1. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case.
   • Tighten to 150 Nm (110 lb-ft).
     Fig 1: Installing New Anti-Lock Speed Sensor On Differential Case

     Courtesy of FORD MOTOR CO.
2. Using special thread sealant, install the ring gear bolts.
   • Tighten to 150 Nm (110 lb-ft).
     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 A 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 Left Bearing Cap
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

   Courtesy of FORD MOTOR CO.
6. Install the right side bearing cap and tighten the bolts.
   • Tighten to 119 Nm (88 lb-ft).
     Fig 6: Installing Right Side Bearing Cap

     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: Using Special Tool Measure 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: Checking Backlash

   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 10: Installing Thicker Shim And Thinner Shim

      Courtesy of FORD MOTOR CO.
11. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 11: Installing Bearing Caps And Bearing Cap

      Courtesy of FORD MOTOR CO.
12. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 12: Rotating Differential Several Times To Make Sure Differential Bearings

    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 13: 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, make sure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 14: Identifying Differential Bearing Shims Fully Seated And Assembly

      Courtesy of FORD MOTOR CO.
15. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 15: Installing Bearing Caps And Bearing Cap

      Courtesy of FORD MOTOR CO.
16. Using the special tool, verify the backlash.
    Fig 16: Using Special Tool Verify Backlash

    Courtesy of FORD MOTOR CO.
17. Install the axle shafts. Refer to AXLE SHAFT .
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 silicone sealant to the differential housing cover.
    Fig 17: Applying A New Continuous Bead Of Silicone Sealant To Differential Housing Cover

    Courtesy of FORD MOTOR CO.