Removal and Installation

Special Tools:

Removal
1. Remove the axle shafts.
2. Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage.

3. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears.

4. NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear back face runout.

Position the special tool and inspect ring gear backlash and ring gear back face runout.

5. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Loosen the differential case.
1 Remove the bearing cap bolts.
2 Remove the bearing caps.

6. To simplify the installation, fabricate two differential case retaining straps from metal stock as shown.

7. WARNING: Be careful not to allow the differential case to fall.

CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage.

Use the pry bar and the wood block to remove the differential case from the rear axle housing.

8. Remove the ring gear bolts.

9. CAUTION: Care should be taken not to damage the ring gear bolt hole thread.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring.

10. Install the differential case.
1 Position the differential case assembly, including bearing cups and shims, in the carrier.
2 Install the differential bearing caps.
3 Install the differential bearing cap bolts.

11. Position the special tool.
1 Rotate the differential case to make sure the differential bearings are correctly seated.
2 Position the special tool.

12. NOTE: If runout is less than specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install both the differential case and the differential bearings new.

Measure the differential case runout without the ring gear.
1 Rotate the differential case.
2 Check and note the differential case runout.

13. Remove the differential case from the rear axle housing, and remove the differential bearings using the special tools.

14. Using the special tool, install the new differential bearings on the differential case.

15. Measure the differential case runout without the ring gear.
- Check the case runout again with the new differential bearings. If the runout is now within the specification shown, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be installed new.

Installation

1. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned.

Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case.

2. Install the ring gear bolts.
- Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts.

3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing.

4. Install a shim on the left side.

5. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.

Install the left bearing cap, and loosely install the bearing cap bolts.

6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.

7. Install the right side bearing cap, and tighten the bolts.

8. Rotate the differential case to make sure it rotates freely.

9. Using the special tool, measure ring gear backlash.
- If the backlash is within specification, go to Step 15. The specification shown in the illustration is the total allowable range.
- If a zero backlash condition occurs, go to Step 10.
- If the backlash is not within specification, go to Step 11.

10. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 min (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step 9.

11. To increase or decrease backlash, remove the bearing caps, and install a thicker shim and a thinner shim as shown.
- If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.

12. Install the bearing caps and bearing cap bolts.

13. Rotate the differential several times to make sure the differential bearings are correctly seated.

14. Using the special tool check the backlash.
- If backlash is within specification, go to Step 15. If not, repeat Step 9.
- The specification shown in the illustration is the total allowable range.

15. Remove the bearing caps and bolts.
- To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
- Using a special tool, ensure the differential bearing shims are fully seated and the assembly turns freely.

16. Install the bearing caps and bearing cap bolts.

17. Using the special tool, verify the backlash.
- The specification shown in the illustration is the total allowable range.

18. Install the axle shafts.