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Differential Carrier: Installation

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    NOTE: Make sure the Dial Indicator needle is in the spreader adapter hole.
    Fig 1: Installing Dial Indicator Gauge With Holding Fixture, Clutch Housing Gauge And Differential Carrier Spreader
    G06125607Courtesy of FORD MOTOR CO.
  1. Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier Spreader.
    2. NOTE: Overspreading may damage the component.
  2. Spread the axle housing to the specification.
    • Remove the Dial Indicator.
      Fig 2: Spreading Axle Housing To Specification
      G06125608Courtesy of FORD MOTOR CO.
    3. NOTE: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces may occur.
  3. Position the differential bearing shims.
    1. Apply a light coating of grease to one side of the differential bearing shims to help hold them in place.
    2. Position the differential bearing shims.
      Fig 3: Identifying Light Coating Of Grease On Side Of Differential Bearing Shims And Differential Bearing Shims
      G06125609Courtesy of FORD MOTOR CO.
    4. NOTE: Push the differential carrier downward to fully seat the differential bearing cups in the axle housing.
  4. Position the differential carrier.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential assembly in place between the differential bearing shims.
      Fig 4: Positioning Differential Carrier
      G06125610Courtesy of FORD MOTOR CO.
  5. Install the differential bearing caps in their original positions and tighten with the housing still spread.
    1. Position the 2 differential bearing caps.
    2. Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    3. Remove the Differential Carrier Spreader.
      Fig 5: Identifying Differential Bearing Caps, Bolts And Differential Carrier Spreader
      G06125611Courtesy of FORD MOTOR CO.
  6. Install the Dial Indicator Gauge with Holding Fixture.
    Fig 6: Identifying Dial Indicator Gauge With Holding Fixture
    G06125612Courtesy of FORD MOTOR CO.
  7. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the differential ring gear backlash at 4 equally spaced points.
    1. Attach the Dial Indicator Gauge with Holding Fixture.
    2. Position the Clutch Housing Gauge tip centrally on a drive tooth.
    3. Zero the Dial Indicator.
    4. Turn the differential ring gear without turning the drive pinion gear.
      Fig 7: Measuring Differential Ring Gear Backlash
      G06125166Courtesy of FORD MOTOR CO.
  8. Install the axle housing tube and the 4 bolts.
    • Tighten to 73 Nm (54 lb-ft).
      Fig 8: Locating Axle Housing Tube And Bolts
      G06125504Courtesy of FORD MOTOR CO.
  9. Install a new stub shaft seal. For additional information, refer to STUB SHAFT PILOT BEARING AND SEAL  .
  10. Install a new circlip on the intermediate shaft end.
    Fig 9: Locating Intermediate Shaft Circlip
    G07957718Courtesy of FORD MOTOR CO.
  11. Insert the intermediate shaft and engage the circlip with the differential side gear.
  12. Remove the axle assembly from the Transmission Holding Fixture and place it on the bench.
    13. NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying the new silicone gasket.
    NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has correctly cured.
  13. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface as shown in the illustration.
    • Use silicone gasket and sealant.
      Fig 10: Locating Continuous Bead Of Sealant On Differential Housing Cover Mounting Surface
      G06125506Courtesy of FORD MOTOR CO.
  14. Install the differential housing cover and the 10 differential housing cover bolts.
    • Tighten to 32 Nm (24 lb-ft).
      Fig 11: Identifying Differential Housing Cover And Bolts
      G06125448Courtesy of FORD MOTOR CO.
  15. Install the axle assembly. For additional information, refer to AXLE ASSEMBLY  .
  16. Remove the fill plug and fill the axle assembly with the specified type and amount of axle lubricant.
    • Tighten the fill plug to 25 Nm (18 lb-ft).
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