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Differential Case RUNOUT Check

WARNING: This page is about a different car, the 2003 Lincoln Navigator and 2003 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tools (1 Of 3)
G01560938Courtesy of FORD MOTOR CO.
Fig 2: Identifying Special Tools (2 Of 3)
G01560939Courtesy of FORD MOTOR CO.
Fig 3: Identifying Special Tools (3 Of 3)
G01560940Courtesy of FORD MOTOR CO.
  1. Remove the front drive axle assembly. For additional information, refer to AXLE ASSEMBLY - FRONT DRIVE .
  2. Remove the axle shafts from the differential assembly. For additional information, refer to AXLE ASSEMBLY - FRONT DRIVE .
    3. CAUTION: Do not damage the aluminium differential housing while carrying out these procedures.
  3. Using the special tools, mount the differential housing to a work bench.
    1. Attach the special tools to the differential housing with four bolts that retain the differential housing cover to the differential housing.
    2. Attach the special tools together with two 3/8 inch x 1-1/2 inch bolts.
      Fig 4: Attaching Special Tools Together With 3/8 Inch X 1-1/2 Inch Bolts
      G01560941Courtesy of FORD MOTOR CO.
  4. Install the special tools, measure and record the differential ring gear backlash between teeth in four opposing places.
    • If the backlash between teeth exceeds the specification of 0.254-0.305 mm (0.010-0.012 in.), the cause may be a warped ring gear, differential bearings, or a damaged differential case. To determine the cause of the excessive backlash, remove the dial indicator and proceed as follows:
      Fig 5: Measuring Differential Ring Gear Backlash Between Teeth In Four Opposing Places
      G01560942Courtesy of FORD MOTOR CO.
  5. Install the special tool by placing the spreader pins in the hole in the Differential Housing (Plate) Spreader.
    Fig 6: Installing Special Tool By Placing Spreader Pins In Hole In Differential Housing (Plate) Spreader
    G01560943Courtesy of FORD MOTOR CO.
  6. Assemble the special tool.
    1. Install the special tool.
    2. Attach the special tool and position the tip in the Differential Housing (Plate) Spreader hole.
      Fig 7: Attaching Special Tool And Position Tip In Differential Housing (Plate) Spreader Hole
      G01560944Courtesy of FORD MOTOR CO.
    7. CAUTION: Overspreading can damage the differential housing.
    NOTE: Tighten and loosen the Differential Carrier Spreader screw several times to normalize the Differential Housing (Plate) Spreader Adapters prior to taking the final Dial Indicator reading.
  7. Spread the differential housing to specifications.
    1. Adjust the Dial Indicator with Holding Fixture to zero.
    2. Tighten the screw until the differential housing is spread to specification.
    3. Remove the Dial Indicator with Holding Fixture and the Clutch Housing Gauge.
      Fig 8: Spreading Differential Housing To Specifications
      G01560945Courtesy of FORD MOTOR CO.
    8. CAUTION: Mark the position and location of the differential bearing caps as the arrows may not be visible.
  8. Remove the bearing caps.
    1. Remove the bolts.
    2. Remove the bearing caps.
      Fig 9: Removing Bearing Caps
      G01560946Courtesy of FORD MOTOR CO.
    9. CAUTION: Use wood blocks to avoid damaging the differential housing.
  9. Remove the differential assembly.
    1. Position the wood blocks at the top and bottom of the differential case.
    2. Pry the differential assembly with the bearing cups and shims out of the differential housing.
    3. Remove the special tool.
      Fig 10: Removing Differential Assembly
      G01560947Courtesy of FORD MOTOR CO.
  10. Separate the bearing shims and cones from the differential assembly and tag them left and right for assembly.
  11. Remove the ring gear.
    • Remove the ten bolts.
    • Use a drift punch to separate the ring gear from the differential case.
      Fig 11: Removing Ring Gear
      G01560948Courtesy of FORD MOTOR CO.
    12. NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating bearing overheating or failure.
    NOTE: It may be necessary to use the Differential Carrier Spreader to carry out this step.
  12. Install the differential case with the bearing cups and all the shims in the housing.
    1. Position the differential case with the bearing cups and shims in their original location.
    2. Install the bearing caps.
    3. Install the bolts.
    4. Rotate the differential case to make sure the bearings have seated correctly.
      Fig 12: Installing Differential Case With Bearing Cups And All Shims In Housing
      G01560949Courtesy of FORD MOTOR CO.
  13. Install the special tool.
    Fig 13: Installing Special Tool
    G01560950Courtesy of FORD MOTOR CO.
  14. Rotate the differential case and check the differential case runout.
    • If the runout does not exceed the specification, install a new ring gear and pinion.
    • If runout exceeds the specification, the ring gear is true and the condition is due to differential case/differential bearing damage.
    1. Inspect the differential bearings and the differential case. Always install new differential bearings when installing a new differential case, or if a bearing condition is questionable.
      Fig 14: Rotating Differential Case And Checking Differential Case Runout
      G01560951Courtesy of FORD MOTOR CO.
  15. Remove the bearing caps, and the differential case with the bearing cups and shims from the housing.
  16. If necessary, using the special tools, remove the differential bearings.
    Fig 15: Removing Differential Bearings
    G01560952Courtesy of FORD MOTOR CO.
    17. CAUTION: Press against the differential bearing inner cone only.
  17. Install the new differential bearings.
    1. Position the appropriate differential bearing (RH or LH).
    2. Using a suitable press and the special tool, install the differential bearing.
    • Repeat the steps for the other differential bearing.
      Fig 16: Installing New Differential Bearings
      G01560953Courtesy of FORD MOTOR CO.
    18. NOTE: It may be necessary to use the Differential Carrier Spreader to carry out this step.
    NOTE: Recheck the flange runout.
  18. Install the differential case with the bearing cups and the shims in the housing.
    1. Position the differential case with the bearing cups and shims in their original location.
    2. Install the bearing caps.
    3. Install the bolts.
    4. Rotate the differential case to make sure the bearings have seated correctly.
      Fig 17: Installing Differential Case With Bearing Cups And Shims In Housing
      G01560954Courtesy of FORD MOTOR CO.
  19. Install the special tool.
    Fig 18: Installing Special Tool
    G01560955Courtesy of FORD MOTOR CO.
    20. NOTE: If the runout is still excessive, install a new differential case.
    Fig 19: Checking Runout With New Differential Bearings
    G01560956Courtesy of FORD MOTOR CO.
  20. Check the runout with the new differential bearings. If the runout does not exceed the specification, use the new differential bearings for assembly.
  21. Remove the bolts.
    Fig 20: Removing Bolts
    G01560957Courtesy of FORD MOTOR CO.
  22. Remove the differential case with the bearing cups and the shims from the housing.
    1. Remove the bearing caps.
    2. Remove the differential case with the bearing cups and the shims from the housing.
      Fig 21: Removing Differential Case With Bearing Cups And Shims From Housing
      G01560958Courtesy of FORD MOTOR CO.
  23. Install the ring gear and the differential assembly. For additional information, refer to AXLE ASSEMBLY - FRONT DRIVE .
  24. Install the axle shafts in the differential assembly. For additional information, refer to AXLE ASSEMBLY - FRONT DRIVE .
  25. Install the front drive axle assembly. For additional information, refer to AXLE ASSEMBLY - FRONT DRIVE .
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