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Differential Ring Gear and Pinion: Installation

WARNING: This page is about a different car, the 2020 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the special tools, install the new differential bearings. Use Special Service Tool: 205-010 (T57L-4221-A2) Installer, Differential Side Bearing.
    GFD458285Courtesy of FORD MOTOR COMPANY
  2. Install the ring gear onto the differential carrier. Align the ring gear using 3 new bolts. Using the general equipment: press the ring gear into place. Use the General Equipment: Hydraulic Press
    GFD458346Courtesy of FORD MOTOR COMPANY
  3. Install the remaining new ring gear bolts.

    Torque: 94 lb.ft (128 Nm)

    GFD458347Courtesy of FORD MOTOR COMPANY
  4. If removed. Using the special tool, install the new drive pinion oil baffle. Use Special Service Tool: 205-D044 (D81T-4221-A) Installer, Differential Carrier Bearing.
    GFD458286Courtesy of FORD MOTOR COMPANY
  5. NOTE: Make sure the drive pinion bearing cups are seated correctly or damage to the components may occur.

    Using the special tools, install the new drive pinion inner and outer bearing cups. Use Special Service Tool: 205-024 (T67P-4616-A) Installer, Drive Pinion Bearing Cup.

    GFD458287Courtesy of FORD MOTOR COMPANY
  6. NOTE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly or damage to the component may occur.
    NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

    Assemble the special tools using the new inner and outer drive pinion bearings. Use Special Service Tool: 205-105 (T76P-4020-A3) Adapter for 205-S127, 205-109 (T76P-4020-A9) Adapter for 205-S127, 205-110 (T76P-4020-A10) Gauge Block, 205-111 (T76P-4020-A11) Handle, 205-129 (T79P-4020-A18) Disc, Guage.

    Torque: 19 lb.in (2.2 Nm)

    GFD458288Courtesy of FORD MOTOR COMPANY
  7. Rotate the special tools several half turns to ensure correct seating of the drive pinion bearings. Use Special Service Tool: 205-110 (T76P-4020-A10) Gauge Block.
    GFD458289Courtesy of FORD MOTOR COMPANY
  8. Install the special tool, the differential bearing caps and the differential bearing cap bolts. Use Special Service Tool: 205-336 (T93P-4020-A) Gauge Tube, Drive Pinion.

    Torque: 77 lb.ft (105 Nm)

    GFD458290Courtesy of FORD MOTOR COMPANY
  9. NOTE: Drive pinion bearing adjustment shims must be flat and clean.
    NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.

    Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.

    • After the correct drive pinion bearing adjustment shim thickness has been determined, remove all of the Adapters. Use Special Service Tool: 205-111 (T76P-4020-A11) Handle, 205-109 (T76P-4020-A9) Adapter for 205-S127, 205-110 (T76P-4020-A10) Gauge Block, 205-129 (T79P-4020-A18) Disc, Guage, 205-336 (T93P-4020-A) Gauge Tube, Drive Pinion.

    GFD458291Courtesy of FORD MOTOR COMPANY
  10. NOTE: The same drive pinion bearing from the previous steps must be used.

    Install the drive pinion bearing and the selected drive pinion bearing adjustment shim until they are firmly seated on the drive pinion. Use Special Service Tool: 205-005 (T53T-4621-C) Installer, Drive Pinion Bearing Cone. Use the General Equipment: Hydraulic Press

    GFD458293Courtesy of FORD MOTOR COMPANY
  11. Install the pinion gear.
    GFD458294Courtesy of FORD MOTOR COMPANY
  12. Install the new drive pinion collapsible spacer.
    GFD458295Courtesy of FORD MOTOR COMPANY
  13. Install the outer drive pinion bearing.
    GFD458279Courtesy of FORD MOTOR COMPANY
  14. Install the outer drive pinion oil slinger.
    GFD458277Courtesy of FORD MOTOR COMPANY
  15. Install the drive pinion flange and seal. Refer to: Drive Pinion Flange and Seal .
  16. NOTE: It is necessary to loosely install the bearing caps and bolts to hold the differential in place.

    Install the differential carrier and the differential carrier bearing cups as a assembly.

    GFD458296Courtesy of FORD MOTOR COMPANY
  17. Install a 6.12 mm (0.241 in) differential bearing shim on the LH side of the differential bearing.
    GFD458297Courtesy of FORD MOTOR COMPANY
  18. NOTE: Apply pressure toward the left side to make sure the left differential bearing cap is seated.

    Install the left differential bearing cap and loosely install the differential bearing cap bolts.

    GFD458298Courtesy of FORD MOTOR COMPANY
  19. NOTE: Apply pressure toward the left side to make sure the left differential bearing cap is seated.

    Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.

    GFD458299Courtesy of FORD MOTOR COMPANY
    1. Install the RH differential bearing cap and bolts.
    2. Tighten the differential bearing cap bolts.

      Torque: 77 lb.ft (105 Nm)

    GFD458300Courtesy of FORD MOTOR COMPANY
  21. Rotate the differential carrier to make sure it turns freely.
    GFD458301Courtesy of FORD MOTOR COMPANY
  22. Using the dial indicator, measure the differential ring gear backlash at 4 equally spaced points.

    • To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

    GFD458302Courtesy of FORD MOTOR COMPANY
  23. NOTE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the differential bearing caps in their original positions or damage to the component may occur.

    Remove the differential cap bolts, differential caps and the carrier assembly.

    GFD458303Courtesy of FORD MOTOR COMPANY
    1. Measure the thickness of the selected right and left bearing shims. Use the General Equipment: Caliper Gauge
    2. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 in).
    GFD458304Courtesy of FORD MOTOR COMPANY
  25. Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier Spreader. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge, 308-021 (T75L-4201-A) Gauge, Clutch Housing, 205-001 (TOOL-4000-E) Spreader, Differential Carrier.
    GFD458305Courtesy of FORD MOTOR COMPANY
  26. NOTE: Overspreading may damage the component. Do not spread the differential housing more then 0.762 mm (0.030 in).
    NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final Dial Indicator reading.

    Spread the differential housing to the specification.

    1. Adjust the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge to zero. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge, 308-021 (T75L-4201-A) Gauge, Clutch Housing.
    2. Tighten the screw until spreading the differential housing to the specification.
    3. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.

    GFD458306Courtesy of FORD MOTOR COMPANY
  27. NOTE: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, the aluminum housing may be damaged.

    Place the differential bearing shims in the differential housing.

    GFD458307Courtesy of FORD MOTOR COMPANY
  28. Install the differential carrier.

    • Position the differential bearing cups on the differential bearings.

    • Lower the differential carrier in place between the differential bearing shims.

    GFD458308Courtesy of FORD MOTOR COMPANY
  29. NOTE: The fixture mounting bolts must have the minimum of 12.7 mm (0.500 In) of thread engagement in the carrier or damage to the component may occur.
    NOTE: Always install the differential bearing caps in their original positions or damage to the component may occur.
    NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.

    • With the differential housing spread to 0.762 mm (0.030 in) maximum. Install the differential caps and bolts in their original locations and positions. Use Special Service Tool: 205-001 (TOOL-4000-E) Spreader, Differential Carrier, 205-368 (T96T-4000-A) Adapter for Differential Housing Spreader, 205-335 (T93P-4000-A) Spreader, Differential Housing (Plate).

    • NOTE: Finger tighten the differential bearing cap bolts prior to releasing the carrier spreader.

      Install the differential bearing caps and the differential bearing cap bolts in their original locations and positions.

    GFD458309Courtesy of FORD MOTOR COMPANY
    1. Loosen and Remove the special tools. Use Special Service Tool: 205-001 (TOOL-4000-E) Spreader, Differential Carrier, 205-368 (T96T-4000-A) Adapter for Differential Housing Spreader, 205-335 (T93P-4000-A) Spreader, Differential Housing (Plate).
    2. Tighten the differential bearing cap bolts.

      Torque: 77 lb.ft (105 Nm)

    GFD458348Courtesy of FORD MOTOR COMPANY
  31. Rotate the differential carrier to make sure it turns freely.
    GFD458301Courtesy of FORD MOTOR COMPANY
  32. Install the Dial Indicator Gauge with Holding Fixture at the 12 o'clock position and recheck the ring gear backlash. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD458302Courtesy of FORD MOTOR COMPANY
  33. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  34. Verify an acceptable pattern check. Refer to: Front Drive Axle .
  35. NOTE: Make sure that the mating surface and the bore is free of corrosion and foreign material, avoid particles getting into the bore. Particles might stick on the vent valve assembly and cause damage to vent valve.

    Clean the mating surface of the axle and the axle tube.

    GFD458312Courtesy of FORD MOTOR COMPANY
  36. Apply a new continuous bead of sealant to the differential housing as shown.

    Material: Silicone Sealant (WSS-M4G323-A8)

    GFD458313Courtesy of FORD MOTOR COMPANY
  37. Install the axle tube and the axle tube bolts.

    Torque: 54 lb.ft (73 Nm)

    GFD458314Courtesy of FORD MOTOR COMPANY
  38. Install the new inner and outer circlips.
    GFD458315Courtesy of FORD MOTOR COMPANY
  39. NOTE: The axle shaft is not fully seated until the circlip is engaged with the differential side gear.

    Install the axle shaft.

    GFD458254Courtesy of FORD MOTOR COMPANY
  40. NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying the new silicone gasket.

    Clean the gasket mating surface of the axle and the differential housing cover.

    GFD458316Courtesy of FORD MOTOR COMPANY
  41. 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.

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

    Material: Silicone Sealant (WSS-M4G323-A8)

    GFD458317Courtesy of FORD MOTOR COMPANY
  42. Install the differential cover and differential cover bolts.

    Torque: 24 lb.ft (32 Nm)

    GFD458318Courtesy of FORD MOTOR COMPANY
  43. Install the front axle assembly. Refer to Axle Assembly 
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