Differential Carrier: Assembly

WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty, 2019 Ford F-450 Super Duty, 2019 Ford F-350 Super Duty, and 2019 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

Vehicles equipped with a 1 piece case

NOTE: Lubricate the differential side gear thrust washers, if equipped wave washers and the side gear journals with axle lubricant.

Position the differential side gear thrust washers and if equipped, wave washers on the differential side gears.

Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL (WSS-M2C942-A)

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Position the differential side gears.

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NOTE: Lubricate both sides of the differential pinion gear thrust washers with axle lubricant.

NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.

Position the differential pinion gears and differential pinion gear thrust washers in the window of the differential case so they mesh with the differential side gear teeth.

Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL (WSS-M2C942-A)

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Rotate the differential pinion gears to align the differential pinion shaft bore.

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Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt.
Torque: 22 lb.ft (30 Nm)

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Vehicles equipped with a 2 piece case
Clean and inspect the differential case.

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Install the LH side gear shim.

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Lubricate and install the LH side gear.
Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL (WSS-M2C942-A)

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Lubricate and install the differential pinion shaft, pinion gears and pinion gear washers.
Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL (WSS-M2C942-A)

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Lubricate and install the RH side gear and side gear shim.
Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL (WSS-M2C942-A)

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Install the carrier case.
1. Install the carrier case.
2. Line up the index mark.. Use the General Equipment: Vise
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Install the differential carrier case bolts.
Torque: Stage 1: 46 lb.ft (63 Nm) | Stage 2: 90 deg.

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All vehicles
NOTE: Tighten the ring gear bolts in a cross pattern.

Install the ring gear and the new ring gear bolts.

Torque: Stage 1: 46 lb.ft (63 Nm) | Stage 2: 60 deg.

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Using the general equipment, install the new differential bearings. Use Special Service Tool: 205-D044 (D81T-4221-A) Installer, Differential Carrier Bearing.. Use the General Equipment: Vise

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Install the differential carrier. Refer to: Differential Carrier .