Differential Case: Installation
WARNING: This page is about a different car, the 2012 Ford Pickup and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
All vehicles
- Install the differential ring gear.
- Place the differential ring gear on the differential case.
- Hand-start 3 new ring gear bolts to align the ring gear and differential case.
- Place the differential assembly on the press bed.
- Press the ring gear into place with the Differential Carrier Bearing Step Plate and a suitable press.
- Install the remaining 9 new ring gear bolts.
- Tighten to 63 Nm (46 lb-ft) and then tighten an additional 60 degrees.
- With the pinion depth set and the pinion installed, place the differential case in the rear axle housing.
- Install a shim on the left side as shown in the illustration.
- Install the left bearing cap and loosely install the 2 bearing cap bolts.
ELD equipped vehicles
- Push the ELD coil electrical connector through the differential case and connect the connector to the new adapter.
- Seat the connector adapter into the differential housing and Install the bolt. Connect the electrical connector.
- Tighten to 15 Nm (133 In lb).
All vehicles
- Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
- Install the right side bearing cap and 2 bolts. Tighten the 4 bearing cap bolts.
- Tighten to 118 Nm (87 lb-ft).
- Rotate the differential case to make sure it rotates freely.
Measuring backlash
- Using the Dial Indicator Gauge with Holding Fixture, measure ring gear backlash.
- If a zero backlash condition occurs, go to Zero backlash in this procedure below.
- If the backlash is not within specification, go to Backlash not within specification in this procedure.
- If the backlash is within specification, go to Backlash within specification in this procedure. The specification shown is the full allowable range. For the preferred range, refer to GENERAL SPECIFICATIONS .
Zero backlash
- If a zero backlash condition occurs, add a 0.50 mm (0.020 in) shim to the RH side and subtract 0.50 mm (0.020 in) from the LH side to allow backlash indication. Check backlash. Repeat Step 8.
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 Backlash not within specification
- To increase or decrease backlash, remove the 4 bolts and 2 bearing caps and install a thicker shim and a thinner shim as shown in illustration.
- If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
- Install the 2 bearing caps and 4 bearing cap bolts.
- Tighten to 118 Nm (87 lb-ft).
- Rotate the differential several times to make sure the differential bearings are correctly seated.
- Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the backlash.
- If backlash is within specification, go to Backlash within specification in this procedure. If not, repeat Step 8.
Backlash within specification
- Remove the 2 bearing caps and 4 bolts.
- To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
- Using the Differential Shim Installer, make sure the differential bearing shims are fully seated and the assembly turns freely.
All vehicles
- Install the 2 bearing caps and 4 bearing cap bolts.
- Tighten to 118 Nm (87 lb-ft).
- Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, verify the backlash.
- Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - FORD .
- Clean the gasket mating surface of the rear axle and the differential housing cover.
- Apply a new, continuous bead of silicone to the differential housing cover as shown in illustration.
- Install the differential cover and the 12 differential housing cover bolts.
- For stamped steel covers, tighten alternately and evenly to 45 Nm (33 lb-ft).
- For cast aluminium covers, tighten alternately and evenly to 32 Nm (24 lb-ft).
- Remove the filler plug, fill the axle to the level shown in illustration with axle lubricant and install the filler plug.
- Tighten to 30 Nm (22 lb-ft).
NOTE:
The bearing caps must be installed in their original locations and positions.
NOTE:
Apply pressure toward the left side to make sure the left bearing is seated.
NOTE:
Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
NOTE:
The differential cover must be installed within 15 minutes of application of the silicone or new sealant must be applied. If possible, allow an hour before filling with lubricant to make sure the sealant has properly cured.
NOTE:
Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.