Item 13, Item 14, Item 18 and Item 26: Selective Snap Ring, Differential Bearing Shim, Differential Case and Differential Bearing Assembly Note

WARNING: This page is about a different car, the 2003 Ford Thunderbird. However, it is still accessible from the selected car via links, so may be relevant.

Install the special tools on the differential case.

Fig 1: Installing Special Tools On Differential Case
Courtesy of FORD MOTOR CO.
Place the differential case with the special tool in the differential housing.

Fig 2: Placing Differential Case With Special Tool In Differential Housing
Courtesy of FORD MOTOR CO.
Position the special tool on the differential case in the differential housing.

Fig 3: Positioning Special Tool On Differential Case in Housing
Courtesy of FORD MOTOR CO.
Install a unique set-up selective snap ring with a thickness of 0.100 inches.

Fig 4: Checking Thickness Of Snap Ring
Courtesy of FORD MOTOR CO.
Position the special tool.

Fig 5: Positioning Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Repeat this step until obtaining a consistent reading.

Fig 6: Differential Bearing Shim Selection Chart

Courtesy of FORD MOTOR CO.

Fig 7: Removing Dial Indicator In Differential Case From Differential Housing

Courtesy of FORD MOTOR CO.

Measure the total end play.
- Attach the special tools and position the indicator tip on the machined surface of the differential case flange.
- Move the differential case to the left and the right (as far as possible).
- Record the reading in Line A.
To determine the snap ring thickness, add lines C, D and E (Example: 0.037 + 0.016 + 0.100 = 0.153 snap ring thickness).

To determine the bearing shim thickness, add lines A, F and G. Subtract line C and D from the sum. Example:
- 0.230 + 0.100 + 0.012 = 0.342
- 0.342 - 0.037 - 0.016 = 0.289 bearing shim thickness
Remove the Dial Indicator and the differential case from the differential housing.
Install the differential ring gear.
1. Place the differential ring gear on the differential case.
2. Hand start three bolts to align the holes in the differential ring gear and the differential case.
3. Place the differential case and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
4. Press the differential ring gear into place.
  
  Fig 8: Installing Differential Ring Gear
  Courtesy of FORD MOTOR CO.
Install the remaining bolts.

Fig 9: Installing Remaining Bolts
Courtesy of FORD MOTOR CO.
Place the differential case with the special tool into the differential housing.

Fig 10: Placing Differential Case With Special Tool Into Differential Housing
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 11: Installing Special Tool
Courtesy of FORD MOTOR CO.
Measure the end play.
- Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
- Rock the differential ring gear to allow full mesh with the drive pinion gear.
- With the gears in full mesh, set the special tool to zero.
- Move the differential case as far as possible to the left and note the reading.
- Record the reading on the differential bearing shim selection procedure Line B.
  - Remove the special tool.
    
    Fig 12: Measuring End Play
    Courtesy of FORD MOTOR CO.
Remove the differential case from the differential housing.

Fig 13: Removing Differential Case From Differential Housing
Courtesy of FORD MOTOR CO.
Remove the bolts. Apply stud and bearing mount to the bolt threads, and reinstall the bolts.

Fig 14: Locating Bolts On Differential Gear
Courtesy of FORD MOTOR CO.
Press the left and right differential bearing on the differential case.

Fig 15: Pressing Left And Right Differential Bearing On Differential Case
Courtesy of FORD MOTOR CO.
Place the differential case and bearing cups in the differential case.

Fig 16: Installing Differential Case
Courtesy of FORD MOTOR CO.

NOTE: Select the correct size selective snap ring using the differential bearing shim selection chart.

NOTE: To determine the thickness of the snap ring to be used, subtract Line B from Line A. Add Lines D and E to the difference. This is the thickness of the snap ring required.

Fig 17: Installing Snap Ring In Differential Housing

Courtesy of FORD MOTOR CO.

Place the selective snap ring in the differential housing.

NOTE: Select the correct size selective bearing shim using the differential bearing shim selection chart.

NOTE: To determine the thickness of the bearing shim to be used, add Lines A, F and G. Subtract Lines C and D from the sum. This is the thickness of the bearing shim required.

Fig 18: Positioning Differential Bearing Shim

Courtesy of FORD MOTOR CO.

Position the differential bearing shim indicated by the bearing shim selection chart.
Using the special tools, seat the differential bearing shim in the differential housing.

Fig 19: Installing Differential Bearing Shim In Differential Housing
Courtesy of FORD MOTOR CO.
Install the differential bearing cap in the original location and tighten the bolts.

Fig 20: Installing Differential Bearing Cap
Courtesy of FORD MOTOR CO.
Using the special tools, measure the differential ring gear backlash at four equally spaced points.
- Attach the special tool.
- Position the special tool tip centrally on a drive tooth.
- Zero the indicator.
- Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.127 mm (0.005 in) to 0.228 mm (0.009 in) and must not vary more than 0.076 mm (0.003 in) between points measured. A backlash variation of more than 0.076 mm (0.003 in) between points checked indicates gear/case runout.
  - If backlash is within specifications, install the differential assembly.
  - To correct for a high or low backlash, proceed as follows.
    
    Fig 21: Measuring Differential Ring Gear Backlash
    Courtesy of FORD MOTOR CO.
To correct for high or low backlash, increase or decrease the thickness of the differential bearing shim and decrease or increase the thickness of the selective snap ring by the same amount. Refer to the following tables when adjusting the backlash. When the backlash is within specifications, install the differential assembly.

Fig 22: Backlash Specifications Chart (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 23: Backlash Specifications Chart (2 Of 2)
Courtesy of FORD MOTOR CO.

Differential Snap Ring Size Chart - 13277 -

Fig 24: Differential Snap Ring Size Chart - 13277 - (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 25: Differential Snap Ring Size Chart - 13277 - (2 Of 2)
Courtesy of FORD MOTOR CO.

Differential Shim Size Chart - 4067 -

Fig 26: Differential Shim Size Chart - 4067 - (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 27: Differential Shim Size Chart - 4067 - (2 Of 2)
Courtesy of FORD MOTOR CO.