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Differential Carrier: Installation

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Positioning Clutch Housing Gauge Needle In Differential Carrier Spreader Adapter Hole
GF0009855Courtesy of FORD MOTOR CO.
  1. Install the special tools.
    • Position the clutch housing gauge needle in the differential carrier spreader adapter hole.
    2. Fig 2: Spreading Differential Housing To Specification
    G03912921Courtesy of FORD MOTOR CO.
    CAUTION: Overspreading can damage the differential housing.
  2. Spread the differential housing to the specification.
    3. Fig 3: Identifying Special Tools (100-002) & (308-021)
    GF0009856Courtesy of FORD MOTOR CO.
  3. Remove the special tools.
    4. Fig 4: Installing Differential Bearing Cups & Differential Case In Differential Housing
    GF0009857Courtesy of FORD MOTOR CO.
    NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the differential housing.
  4. Install the differential bearing cups and the differential assembly in the differential housing.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential assembly in place.
    5. Fig 5: Locating Differential Bearing Cap And Bolts
    GF0009858Courtesy of FORD MOTOR CO.
    CAUTION: Do not tighten the differential bearing cap bolts to specification at this time.
  5. Install the differential bearing caps in their original positions.
    1. Position the differential bearing caps.
    2. Install the differential bearing cap bolts hand-tight.
  6. Remove the special tools.
    7. Fig 6: Locating Differential Bearing Cap Bolts
    GF0009859Courtesy of FORD MOTOR CO.
  7. Tighten the differential bearing cap bolts.
    • Tighten to 61 Nm (45 lb-ft).
  8. Verify that the differential assembly rotates freely.
    9. Fig 7: Measuring Differential Ring Gear Backlash Using Special Tools
    G03912927Courtesy of FORD MOTOR CO.
  9. Check the ring gear backlash and remove the special tools.
  10. Install the RH axle shaft.
    11. Fig 8: Applying Continuous Bead Of Sealant To Differential Housing Cover Mounting Surface
    GF0009862Courtesy of FORD MOTOR CO.
    CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.
    CAUTION: Install the differential housing cover within 15 minutes of applying the silicone material.
    CAUTION: Allow the sealant to cure for one hour before filling the axle with lubricant.
  11. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
  12. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 29 Nm (21 lb-ft).
  13. Install the axle assembly. For additional information, refer to Axle Assembly .
  14. Fill the axle with 1.54 liters (3.25 pints) of lubricant.
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