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Home >> Ford >> 2004 >> Explorer 4.0 E, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 266 (Driveline System) >> Disassembly And Assembly >> Front Axle Assembly >> Disassembly & Assembly >> Item 14: Differential Case Assembly Note
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Item 14: Differential Case Assembly Note

WARNING: This page is about a different car, the 2003 Mercury Mountaineer and 2003 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the special tools.
    • Position the clutch housing gauge needle in the differential carrier spreader adapter hole.
    Fig 1: Positioning Clutch Housing Gauge Needle In Differential Carrier Spreader Adapter Hole
    G01270976Courtesy of FORD MOTOR CO.
    2. CAUTION: Overspreading can damage the differential housing.
    Fig 2: Spreading Differential Housing To Specification
    G01270977Courtesy of FORD MOTOR CO.
  2. Spread the differential housing to the specification.
  3. Remove the special tools.
    Fig 3: Removing Special Tools
    G01270978Courtesy of FORD MOTOR CO.
    4. NOTE: Push the differential case downward to fully seat the differential bearing cups in the differential housing.
    Fig 4: Installing Differential Bearing Cups & Differential Case In Differential Housing
    G01270979Courtesy of FORD MOTOR CO.
  4. Install the differential bearing cups and the differential case in the differential housing.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential case in place.
    5. CAUTION: Do not tighten the bolts to specification at this time.
    Fig 5: Installing Differential Bearing Caps Bolts Hand-Tight
    G01270980Courtesy of FORD MOTOR CO.
  5. Install the differential bearing caps in their original positions.
    1. Position the differential bearing caps.
    2. Install the bolts hand-tight.
  6. Remove the special tools.
    Fig 6: Removing Special Tools
    G01270981Courtesy of FORD MOTOR CO.
  7. Tighten the bolts.
    Fig 7: Installing Differential Bearing Caps Bolts
    G01270982Courtesy of FORD MOTOR CO.
  8. Verify that the differential case rotates freely.
  9. Using the special tools, measure the backlash at three equally spaced points on the differential ring gear.
    1. Mount the special tool.
    2. Position the special tool.
    3. Zero the indicator.
    4. Turn the differential ring gear without turning the pinion gear. Record the measurement.
    • The backlash tolerance is 0.13 mm (0.005 in) to 0.20 mm (0.008 in) and cannot vary more than 0.05 mm (0.002 in) between points checked. A backlash variation of more than 0.005 mm (0.002 in) indicates gear/case runout.
    • If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.
    Fig 8: Measuring Backlash
    G01270983Courtesy of FORD MOTOR CO.
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