Differential Case: Installation

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
Courtesy 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 On Differential Case
Courtesy of FORD MOTOR CO.
NOTE: Clean the threads of the ring gear bolts. Make sure they are free of foreign material.
3. Install the 10 bolts.
   • Apply stud and bearing mount to the bolt threads.
     • Tighten to 114 Nm (84 lb-ft).
Fig 3: Identifying Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.
4. With the pinion depth set and pinion installed, place the differential assembly in the differential housing.
Fig 4: Positioning Differential Assembly In Axle Housing
Courtesy of FORD MOTOR CO.
5. Install a differential bearing shim on the left side.
Fig 5: Locating Differential Bearing Shim
Courtesy of FORD MOTOR CO.
CAUTION: Always install the differential bearing caps in their original locations and positions.
NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly.
6. Install the left differential bearing cap and loosely install the 2 bolts.
Fig 6: Identifying LH Differential Bearing Cap And Bolts
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
8. Install the right side differential bearing cap and tighten the 2 left side and 2 right side bolts.
   • Tighten to 114 Nm (84 lb-ft).
Fig 8: Identifying Bearing Caps & Bolts
Courtesy of FORD MOTOR CO.
9. Rotate the differential case to make sure it turns freely.

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.
    • If a zero backlash condition occurs, refer to Zero backlash in this procedure.
    • If backlash is not within the specification, refer to Backlash not within specification in this procedure.

      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: Checking Differential Ring Gear Backlash (With Specifications)
Courtesy of FORD MOTOR CO.

Zero backlash 

11. If a zero backlash condition occurs, add 0.51 mm (0.020 in) to the RH side and subtract 0.51 mm (0.020 in) from the LH side to allow backlash indication. Measure the backlash. Refer to Measuring backlash in this procedure.
Fig 10: Identifying Differential Bearing Shims
Courtesy of FORD MOTOR CO.

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: Identifying Differential Bearing Shims
Courtesy 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. If backlash is not within the specification, repeat Backlash not within specification in this procedure.
Fig 12: Checking Differential Ring Gear Backlash (With Specifications)
Courtesy of FORD MOTOR CO.

Backlash within specification 

15. Remove the 4 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 in illustration.
Fig 13: Identifying Differential Bearing Shim For Preload (With Specifications)
Courtesy 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
Courtesy of FORD MOTOR CO.
18. Install the 2 differential bearing caps and 4 bolts.
    • Tighten to 114 Nm (84 lb-ft).
Fig 15: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
19. Using the special tools, recheck the backlash.
Fig 16: Checking Differential Ring Gear Backlash (With Specifications)
Courtesy of FORD MOTOR CO.
WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article. Failure to follow these instructions may result in serious personal injury.
20. Install the axle shafts. For additional information, refer to Axle Shaft .