Differential Carrier: Installation

WARNING: This page is about a different car, the 2016 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.

1.

NOTE: Make sure the Dial Indicator needle is in the spreader adapter hole.

Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier Spreader.

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2.

NOTE: Overspreading may damage the component.

Spread the axle housing to the specification.
- Remove the Dial Indicator.

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3.

NOTE: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces may occur.

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.

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4.

NOTE: Push the differential carrier downward to fully seat the differential bearing cups in the axle housing.

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.

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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.

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6.

Install the Dial Indicator Gauge with Holding Fixture.

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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.

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8.

Install the axle housing tube and the 4 bolts.
- Tighten to 73 Nm (54 lb-ft).

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9.

Install a new stub shaft seal. Refer to Stub Shaft Pilot Bearing and Seal .

10.

Install a new circlip on the intermediate shaft end.

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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.

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.

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14.

Install the differential housing cover and the 10 differential housing cover bolts.
- Tighten to 32 Nm (24 lb-ft).

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15.

Install the axle assembly. 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).