Differential Case and Ring Gear - Conventional

Differential Case and Ring Gear - Conventional





















Disassembly

1. Remove the differential carrier. For additional information, refer to Differential Carrier Differential Carrier.

2. Remove and discard the 12 differential ring gear bolts.





3. Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.





4. If necessary, remove the differential bearings with the 2-Jaw Puller and Step Plate.





5. Remove the differential pinion shaft lock bolt and the differential pinion shaft.





6. Install the Differential Gauge in a suitable vise.





7. Install the differential case on the Differential Gauge.





8. NOTE: Apply a small amount of grease to the centering hole of the Differential Gauge step plate.

Install the Differential Gauge step plate in the bottom differential side gear.





9. Install the Differential Gauge nut in the upper differential side gear. Hold the nut in position while installing the Differential Gauge hex screw. Tighten the hex-head screw until contact is made with the step plate.





10. NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened.

Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gears away from the differential pinion gears.





11. Rotate and remove the differential pinion gears and differential pinion gear thrust washers.





12. Remove the differential side gears, the differential side gear thrust washers and the differential side gear wave washers.





Assembly

1. Position the differential side gear thrust washers and wave washers on the differential side gears.
- Lubricate the differential side gear thrust washers, wave washers and the differential side gear journals with axle lubricant.





2. Position the differential side gears.





3. NOTE: Apply a small amount of grease to the step plate bore.

NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.

Assemble the Differential Gauge to the differential case.

1. Position the Differential Gauge step plate in the bottom differential side gear.

2. Position the Differential Gauge hex screw plate in the top differential side gear and hold it in place.

3. Install the Differential Gauge hex screw and tighten it 2 turns after it contacts the bottom step plate.





4. NOTE: Lubricate both sides of the differential pinion gear thrust washers with axle lubricant.

NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.

Position the differential pinion gears and differential pinion gear thrust washers in the window of the differential case so they mesh with the differential side gear teeth.





5. Engage the differential pinion gears opposite the differential side gears.





6. Rotate the differential pinion gears to align the differential pinion shaft bore.





7. Remove the Differential Gauges after verifying the differential pinion shaft bore alignment.

8. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.





9. If removed, use the Differential Carrier Bearing Installer to install the differential bearings.





10. Install the ring gear.

1. Place the ring gear on the differential assembly.

2. Hand-start 3 new ring gear bolts to align the holes in the ring gear and the differential case.

3. Using a suitable press, position the ring gear.

4. Press the ring gear into place.





NOTE: Apply stud and bearing mount to the differential ring gear bolts.

11. Hand-start the remaining 9 new differential ring gear bolts. Tighten the 12 bolts in 2 stages.
- Stage 1: Tighten to 60 Nm (44 lb-ft).

- Stage 2: Tighten an additional 90 degrees.





12. Install the differential assembly in the axle housing.





13. NOTE: Install the differential bearing shims with the chamfer facing outboard.

Install a differential bearing shim on the LH side.

14. NOTE: Index-mark the position of the differential bearing caps as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.

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

Install the LH differential bearing cap and loosely install the 2 differential bearing cap bolts.





15. NOTE: Install the differential bearing shims with the chamfer facing outboard.

Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.





16. Install the RH side differential bearing cap and tighten the 2 LH side and 2 RH side differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).





17. Rotate the differential assembly to make sure it rotates freely.





18. NOTE: If ring gear backlash is within specification, go to Step 21.

NOTE: Specification shown is the maximum ring gear backlash allowable.

Using the Dial Indicator Gauge With Bracketry and the Clutch Housing Gauge, measure ring gear backlash.

- Turn the ring gear without turning the pinion gear and record the measurement.





19. NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.

To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.

- If ring gear 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.






20. NOTE: Install the differential bearing shims with the chamfer facing outboard.

NOTE: The bearing caps must be removed before differential bearing shims can be installed.

To decrease ring gear backlash, install a thicker differential bearing shim on the LH side and a thinner differential bearing shim of the same thickness change on the RH side.





21. Rotate the differential assembly several times to make sure the differential bearings are seated.





22. Using the Dial Indicator Gauge With Bracketry and the Clutch Housing Gauge, recheck the ring gear backlash.





23. Remove the 4 differential bearing cap bolts and the 2 differential bearing caps.





24. NOTE: Install the differential bearing shims with the chamfer facing outboard.

NOTE: To establish differential bearing preload, increase both left and right differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.

Using the Shim Driver, install the differential bearing shims.





25. Install the 2 differential bearing caps and the 4 differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).





26. Apply high contrast hypoid gear marking compound and rotate the differential assembly 5 complete revolutions.

27. Verify an acceptable pattern check.

28. NOTE: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant to the differential housing cover. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the axle and the differential housing cover.

29. Install the axle shafts. For additional information, refer to Axle Shaft Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear.