Disassembly And Assembly Of Subassemblies: Differential: Assembly

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Align the locking tabs and install the speedometer drive gear.

Fig 1: Locating Speedometer Drive Gear
Courtesy of FORD MOTOR CO.
Using the Differential Bearing Cup Installer and a suitable press, press the differential bearing onto the differential case.
- Always install new bearings and cups as a set.
NOTE: Press the differential bearings onto the differential case by the inner race only. Pressing on the outer race will damage the bearing.

Fig 2: Pressing Differential Bearing Onto Differential Case
Courtesy of FORD MOTOR CO.
Rotate the differential case. Using the Differential Bearing Cup Installer and a suitable press, press on the differential bearing.
- Always install new bearings and cups as a set.
Fig 3: Locating Differential Bearing
Courtesy of FORD MOTOR CO.
Install the differential pinion gears and thrust washers.
Install the differential pinion shaft.
Install the new differential pinion shaft lock pin.

Fig 4: Locating Differential Pinion Shaft Lock Pin
Courtesy of FORD MOTOR CO.
Install the differential side gears and thrust washers.
Measure the differential backlash using the following steps in the following sequence:
1. Install the LH and RH halfshafts in the differential.
2. Support the halfshafts on V-blocks as shown in illustration.
3. Using the Dial Indicator Gauge with Holding Fixture, measure the backlash of both pinion gears.
  - If not within specification, replace worn and damaged parts.
Fig 5: Measuring Backlash Of Both Pinion Gears
Courtesy of FORD MOTOR CO.