Differential Carrier: Installation

All vehicles 

1. NOTE: The gasket material should cure for one hour before filling the axle with lubricant.

   Apply a continuous bead of gasket maker onto the axle housing mounting flange and around each bolt hole as shown below.

   Fig 1: Locating Continuous Bead Of Gasket Maker Applying Area Onto Axle Housing Mounting Flange And Around Each Bolt Hole

   Courtesy of FORD MOTOR CO.
2. Thread 2 studs into the axle housing. This will eliminate rotation of the carrier assembly after it makes contact with the gasket material.
   Fig 2: Locating Studs Into Axle Housing

   Courtesy of FORD MOTOR CO.
3. WARNING: Always secure transmission, transfer case, and axle assemblies to their service jack. Avoid obstructions while lowering and raising the jack. Improperly secured assemblies or contact with obstructions may cause the assembly to fall off the jack, which could result in serious personal injury.

   Position the carrier into the axle housing, using the 2 studs to align the carrier and housing.

   Fig 3: Positioning Carrier Into Axle Housing

   Courtesy of FORD MOTOR CO.
4. NOTE: Make sure the bolt threads are clean.
   NOTE: Remove the 2 alignment studs only after installing several of the bolts.

   Install 14 new differential carrier housing bolts.

   • Tighten alternately and evenly to 203 Nm (150 lb-ft).
     Fig 4: Locating Differential Carrier Housing Bolts

     Courtesy of FORD MOTOR CO.
5. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .

   Vehicles with split pin yoke 

6. Position the driveshaft. Install the 2 U-joint straps and 4 new bolts.
   • Tighten the 62 Nm (46 lb-ft).
     Fig 5: Locating Driveshaft Bolts

     Courtesy of FORD MOTOR CO.

   Vehicles with circular flange 

7. Position the driveshaft. Install the 4 new bolts.
   • Tighten to 100 Nm (74 lb-ft).

   All vehicles 

8. Connect the rear wheel speed sensor electrical connector.
   Fig 6: Locating Rear Wheel Speed Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
9. Remove the fill plug.
   Fig 7: Locating Fill Plug

   Courtesy of FORD MOTOR CO.
10. NOTE: A lubricant level close enough to the bottom of the fill hole to be seen or touched is not sufficient. The lubricant must be level with the fill hole.

    Fill the axle with axle lubricant until the lubricant is level with the fill hole.

11. Clean and install the fill plug.
    • Tighten to 68 Nm (50 lb-ft).
      Fig 8: Locating Fill Plug

      Courtesy of FORD MOTOR CO.
12. Remove the wheel chocks.
13. Release the parking brake.