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Differential Case: Installation

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. Using the special tool, install the new differential bearings.
    1. Position the bearings.
    2. Using the special tool, press the bearings on the differential case.
      Fig 1: Installing Differential Bearings
      G03878661Courtesy of FORD MOTOR CO.
  2. Position the differential ring gear and the differential case. Align the bolt holes by starting 2 bolts through the holes in the differential case and the differential ring gear. Press the differential ring gear on the differential case.
    Fig 2: Pressing Differential Ring Gear Onto Differential Case
    G03878550Courtesy of FORD MOTOR CO.
    3. NOTE: Clean the threads of the ring gear bolts. Make sure they are free of foreign material.
  3. Install the bolts.
    • Apply stud and bearing mount to the bolt threads.
      • Tighten to 114 Nm (84 lb-ft).
        Fig 3: Identifying Differential Ring Gear Bolts
        G03878612Courtesy of FORD MOTOR CO.
  4. With the pinion depth set and pinion installed, place the differential assembly in the differential housing.
    Fig 4: View Of Differential Assembly In Axle Housing
    G03878552Courtesy of FORD MOTOR CO.
  5. Install a differential bearing shim on the left side.
    Fig 5: Identifying Differential Bearing Shim On Left Side
    G03878553Courtesy of FORD MOTOR CO.
    6. CAUTION: Always install the differential bearing caps in their identified locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly.
    Fig 6: Identifying LH Differential Bearing Cap And Bolts
    G03878615Courtesy of FORD MOTOR CO.
  6. Install the left differential bearing cap and loosely install the bolts.
  7. Install progressively larger differential bearing shims on the right side until the largest shim selected can be installed by hand.
    Fig 7: Identifying Differential Bearing Shim
    G03878555Courtesy of FORD MOTOR CO.
  8. Install the right side differential bearing cap and tighten the left side and right side bolts.
    • Tighten to 114 Nm (84 lb-ft).
      Fig 8: Identifying Bearing Caps & Bolts
      G03878621Courtesy of FORD MOTOR CO.
  9. Rotate the differential case to make sure it turns freely.

    10. Measuring backlash 

  10. Using the special tools, measure and note the differential ring gear backlash.
    • If backlash is within the specification, refer to Backlash within specification in this procedure. See step  15.
    • If a zero backlash condition occurs, refer to Zero backlash in this procedure. See step  11.
    • If backlash is not within the specification, refer to Backlash not within specification in this procedure. See step  12.
    BACKLASH ADJUSTMENT CHART

    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
    Fig 9: Measuring Differential Ring Gear Backlash
    G04582940Courtesy of FORD MOTOR CO.

    11. Zero backlash 

  11. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Measure the backlash. See step  10.
    Fig 10: Locating Bearing Caps
    G04582941Courtesy of FORD MOTOR CO.

    12. Backlash not within specification 

  12. To increase or decrease backlash, remove the differential bearing caps and install a thicker shim and a thinner shim accordingly.
    • If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.
      Fig 11: Locating Bearing Caps
      G04582942Courtesy of FORD MOTOR CO.
  13. Rotate the differential assembly several times to verify that the differential bearings seated correctly.
  14. Using the special tools, recheck the backlash.
    • If backlash is within the specification, refer to Backlash Within Specification in this procedure. See step  15. If backlash is not within the specification, repeat Backlash not within specification in this procedure. See step  12.
      Fig 12: Measuring Differential Ring Gear Backlash
      G04582943Courtesy of FORD MOTOR CO.

    15. Backlash within specification 

  15. Remove the bolts and the differential bearing caps.
  16. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.
    Fig 13: Identifying Correct Differential Bearing Shim
    G04582944Courtesy of FORD MOTOR CO.
  17. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 14: Seating Differential Bearing Shims Using Special Tool
    G03878620Courtesy of FORD MOTOR CO.
  18. Install the differential bearing caps and bolts.
    • Tighten to 114 Nm (84 lb-ft).
      Fig 15: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
      G03878679Courtesy of FORD MOTOR CO.
  19. Using the special tools, recheck the backlash.
    Fig 16: Measuring Differential Ring Gear Backlash
    G04582947Courtesy of FORD MOTOR CO.
    20. WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .
  20. Install the axle shafts. For additional information, refer to AXLE SHAFT .
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