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Item 25: Differential Bearing Shim 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 tool.
    Fig 1: Installing Special Tool
    G01270952Courtesy of FORD MOTOR CO.
  2. Install the differential case in the differential housing.
    Fig 2: Installing Differential Case In Differential Housing
    G01270953Courtesy of FORD MOTOR CO.
    3. NOTE: Repeat this step until obtaining a consistent reading.
    Fig 3: Measuring Total End Play
    G01270954Courtesy of FORD MOTOR CO.
  3. Measure the total end play.
    1. Install the special tool.
    2. Force the differential case as far as possible away from the indicator. Position the indicator tip on the machined surface and adjust it to measure full travel. With force still applied, set the indicator to zero.
    3. Force the differential case as far as possible in the opposite direction.
    4. Record the total end play reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A in this procedure.
  4. Remove the special tool, then remove the differential case.
    1. Remove the special tool.
    2. Remove the differential case.
    Fig 4: Removing Differential Case
    G01270955Courtesy of FORD MOTOR CO.
    5. CAUTION: Do not reuse the original bolts.
    Fig 5: Installing Differential Ring Gear
    G01270956Courtesy of FORD MOTOR CO.
  5. Using a suitable press, install the differential ring gear.
    1. Position the differential ring gear and the differential case. Start two or three new bolts to align the holes in the ring gear and the differential case.
    2. Using a suitable press, install the differential ring gear.
  6. Install the remaining new bolts. Tighten all of the bolts to specification.
    Fig 6: Installing Differential Ring Gear Bolts
    G01270957Courtesy of FORD MOTOR CO.
  7. Install the special tool, and position the assembly in the differential housing.
    1. Install the special tool.
    2. Position the assembly in the differential housing.
    Fig 7: Positioning Differential Case Assembly In Differential Housing
    G01270958Courtesy of FORD MOTOR CO.
  8. Position the special tool.
    Fig 8: Positioning Special Tool
    G01270959Courtesy of FORD MOTOR CO.
  9. Force the differential ring gear into mesh with the pinion gear (zero backlash). With force still applied, set the special tool to zero.
    Fig 9: Forcing Differential Ring Gear Into Mesh With Pinion Gear (Zero Backlash)
    G01270960Courtesy of FORD MOTOR CO.
  10. Force the differential ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line D in this procedure.
    Fig 10: Forceing Differential Ring Gear Away From Pinion Gear
    G01270961Courtesy of FORD MOTOR CO.
  11. Remove the special tool.
    Fig 11: Removing Special Tool
    G01270962Courtesy of FORD MOTOR CO.
  12. Remove the differential case from the differential housing. Remove the special tool from the differential case hubs.
    Fig 12: Removing Differential Case From Differential Housing
    G01270963Courtesy of FORD MOTOR CO.
  13. Complete the worksheet, and select the appropriate thickness differential shims. New differential shims are available in 0.0762 mm (0.003 in), 0.127 mm (0.005 in), 0.254 mm (0.010 in), and 0.762 mm (0.030 in) thickness.
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