Differential Case: Installation

All vehicles 

1. Using the special tool, install the new differential bearings.
   Fig 1: Installing New Differential Bearings

   Courtesy of FORD MOTOR CO.
2. Position the differential ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear.

   Press the differential ring gear on the differential case.

   Fig 2: Positioning Differential Ring Gear And Differential Case

   Courtesy of FORD MOTOR CO.
3. Install the bolts.
   • Apply stud and bearing mount to the bolt threads.
     Fig 3: Applying Stud And Bearing Mount To Bolt Threads

     Courtesy of FORD MOTOR CO.
4. With the pinion depth set and pinion installed, place the differential assembly in the differential housing.
   Fig 4: Placing Differential Assembly In Differential Housing

   Courtesy of FORD MOTOR CO.
5. Install a differential bearing shim on the left side.
   Fig 5: Installing Differential Bearing Shim On Left Side

   Courtesy of FORD MOTOR CO.
CAUTION: Always install the differential bearing caps in their identified locations and positions.
NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats correctly.
Fig 6: Removing Left Differential Bearing Cap And Loosely Install Bolts
Courtesy of FORD MOTOR CO.
6. Install the left differential bearing cap and loosely install the bolts.
7. Install progressively larger differential bearing shims on the right side until the largest shim selected can be installed by hand.
   Fig 7: Installing Progressively Larger Differential Bearing Shims On Right Side

   Courtesy of FORD MOTOR CO.
8. Install the right side differential bearing cap and tighten the left side and right side bolts to specification.
   Fig 8: Installing Right Side Differential Bearing Cap

   Courtesy of FORD MOTOR CO.
9. Rotate the differential case to make sure it turns freely.
   Fig 9: Rotating Differential Case To Make Sure It Turns Freely

   Courtesy of FORD MOTOR CO.

   Measuring backlash 

10. Using the special tools, measure and note the differential ring gear backlash.
    • If backlash is within the specification, refer to Backlash within specification in this procedure.
    • If a zero backlash condition occurs, refer to Zero backlash in this procedure.
    • If backlash is not within the specification, refer to Backlash not within specification in this procedure.
      Fig 10: Backlash Measuring Table

      Courtesy of FORD MOTOR CO.
      Fig 11: Measuring Backlash

      Courtesy of FORD MOTOR CO.

    Zero backlash 

11. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Measure the backlash. Refer to Measuring backlash in this procedure.
    Fig 12: View Of Differential (Zero Backlash)

    Courtesy of FORD MOTOR CO.

    Backlash not within specification 

12. To increase or decrease backlash, remove the differential bearing caps and install a thicker shim and a thinner shim accordingly.
    • If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.
      Fig 13: Increasing Or Decreasing Backlash

      Courtesy of FORD MOTOR CO.
13. Rotate the differential assembly several times to verify that the differential bearings seated correctly.
    Fig 14: Rotating Differential Assembly Several Times To Verify That Differential Bearings Seated Correctly

    Courtesy of FORD MOTOR CO.
14. Using the special tools, recheck the backlash.
    • If backlash is within the specification, refer to Backlash within specification in this procedure. If backlash is not within the specification, repeat Backlash not within specification in this procedure.
      Fig 15: Recheck Backlash Using Special Tools

      Courtesy of FORD MOTOR CO.

      Backlash within specification 

15. Remove the bolts and the differential bearing caps.
16. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.
    Fig 16: Removing Differential Bearing Caps

    Courtesy of FORD MOTOR CO.
17. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 17: Making Sure Assembly Rotates Freely

    Courtesy of FORD MOTOR CO.
18. Install the differential bearing caps and bolts.
    Fig 18: Installing Differential Bearing Caps

    Courtesy of FORD MOTOR CO.
19. Using the special tools, recheck the backlash.
    Fig 19: Rechecking Backlash Using Special Tools

    Courtesy of FORD MOTOR CO.
20. Install the axle shafts. For additional information, refer to AXLE SHAFT .