Differential Case: Installation

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

Install the outboard spacers in the side from which they were removed.

Fig 1: Installing Outboard Spacers
Courtesy of FORD MOTOR CO.
NOTE: Remove all nicks, burrs and dirt from the differential case hubs to allow the Dummy Bearing Set to rotate freely.

Place the Dummy Bearing Set on the differential case hubs and position the assembly into the differential housing.

Fig 2: Identifying Dummy Bearing Set On Differential Case Hub
Courtesy of FORD MOTOR CO.
NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.

Mount the Dummy Bearing Set and Dial Indicator Gauge with Holding Fixture as shown below.

Fig 3: Mounting Dummy Bearing Set And Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.
NOTE: Repeat this and the following step until the same readings appear on the Dial Indicator Gauge each time. This is the total differential bearing shim thickness necessary, less preload. The final calculation occurs later during assembly.

Force the differential case as far as possible toward the Dial Indicator Gauge. With force applied, set the Dial Indicator Gauge at 0. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
- Contact Spicer Service at 1-800-826-4357 for assistance with differential case runout results and further diagnosis.
  
  Fig 4: Inspecting Total Differential Case End Play
  Courtesy of FORD MOTOR CO.
After making sure the reading is repeatable, remove the differential case from the differential housing. Do not remove the Dummy Bearing Set from the differential case at this time.
Start 2 new bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and differential case align.

Fig 5: Locating Differential Ring Gear And Differential Case Alignment Bolts
Courtesy of FORD MOTOR CO.
Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.

Fig 6: Pressing Anti-Lock Speed Sensor Onto Differential Case
Courtesy of FORD MOTOR CO.
Draw up the 12 new ring gear bolts alternately and evenly.
- Tighten to 298 Nm (220 lb-ft).
  
  Fig 7: Identifying Ring Gear With Bolts
  Courtesy of FORD MOTOR CO.
Place the differential assembly with the Dummy Bearing Set in the differential housing.

Fig 8: Placing Differential Assembly With Dummy Bearing Set In Differential Housing
Courtesy of FORD MOTOR CO.
Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge. Locate the tip of the Clutch Housing Gauge on the flat surface of one of the bolts.

Fig 9: Identifying Dial Indicator Gauge With Holding Fixture And Clutch Housing Gauge
Courtesy of FORD MOTOR CO.
NOTE: Repeat this and the following step until the same readings appear on the Dial Indicator Gauge each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.

Force the differential case and ring gear away from the drive pinion. With force applied, set the Dial Indicator Gauge to 0.

Fig 10: Forcing Differential Case And Ring Gear Away From Drive Pinion
Courtesy of FORD MOTOR CO.
Force the differential ring gear into mesh with the pinion to obtain a Dial Indicator Gauge reading. Record this measurement.

Fig 11: Forcing Differential Ring Gear Into Mesh With Pinion
Courtesy of FORD MOTOR CO.
Remove the differential case from the differential housing.
Remove the Dummy Bearing Set from the differential case.
Place a shim of the thickness determined by the end play between the differential case and the ring gear/pinion on the ring gear side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
Using the Differential Carrier Bearing Installer, install the new differential bearing on the differential ring gear side of the differential case.

Fig 12: Installing Differential Bearing On Differential Case
Courtesy of FORD MOTOR CO.
Determine the correct shim thickness and place the shim on the differential case hub on the drive pinion side.
- To determine the correct shim thickness, first subtract the thickness of the ring gear side differential case hub shim from the total differential case end play reading recorded earlier. Then, add 0.25 mm (0.010 in) to this amount. This result is the correct thickness of shim to place on the pinion side differential hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
Using the Differential Carrier Bearing Installer, install the differential bearing.
1. Place the Differential Carrier Bearing Step Plate on the differential bearing to protect it during the installation of the opposite bearing.
2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.
  
  Fig 13: Installing Differential Bearing
  Courtesy of FORD MOTOR CO.
Assemble the differential bearing cups to the differential bearings.
NOTE: Do not spread the differential housing more than specified or damage to the housing may occur.

NOTE: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly or damage to the component may occur.

Using the Differential Carrier Spreader and Dial Indicator Gauge with Holding Fixture, spread the differential housing to specifications and position the differential assembly.
- Use a rawhide hammer to seat the differential in the differential housing.
  
  Fig 14: Spreading Differential Housing Using Differential Carrier Spreader
  Courtesy of FORD MOTOR CO.
NOTE: Match the mating letters as noted during disassembly.

Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
- Tighten to 108 Nm (80 lb-ft).
  
  Fig 15: Locating Mating Letters Stamped On Bearing Caps And Differential Housing
  Courtesy of FORD MOTOR CO.
Carry out the Tooth Contact Pattern Check to verify that the final pinion position is correct. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.

Apply a continuous bead of sealant to the differential housing cover as shown below.

Fig 16: Locating Sealant Applying Areas On Differential Housing Cover
Courtesy of FORD MOTOR CO.
Install the differential housing cover and the 10 bolts.
- Tighten alternately and evenly to 45 Nm (33 lb-ft).
  
  Fig 17: Locating Differential Housing Cover Bolts
  Courtesy of FORD MOTOR CO.
NOTE: If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.

Fill the axle with the specified type and amount of lubricant.