Operation CHARM: Car repair manuals for everyone.

Differential Case




Differential Case





















Removal

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Remove the 12 differential housing cover bolts and drain the lubricant from the rear axle housing.





3. Remove the differential housing cover.

4. Remove the axle shafts. For additional information, refer to Wheel Hubs and Bearings - Full Floating Axle - Ford Wheel Hubs and Bearings - Full Floating Axle - Ford.

5. Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage.

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





7. Positioning the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, inspect ring gear backlash.





8. 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.

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





ELD equipped vehicles

9. Disconnect the ELD electrical connector and remove the bolt that holds the connector adapter to the housing.





10. Pull the connector adapter out and disconnect the ELD coil electrical connector from the connector adapter. Discard the adapter.





All vehicles

11. NOTICE: 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.





12. Remove and discard the 12 ring gear bolts.





13. NOTICE: Care should be taken not to damage the ring gear bolt hole threads.

Insert a punch in the bolt holes. Drive off the ring gear.





14. Install the differential case without the ring gear.

1. Position the differential case assembly, including bearing clips and shims, in the housing.

2. Install the 2 differential bearing caps.

3. Install the 4 differential bearing cap bolts.

- Tighten to 118 Nm (87 lb-ft).





15. NOTE: Rotate the differential case to make sure the differential bearings are correctly seated.

NOTE: If runout is within 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 damaged, install new differential bearings.

Measure the differential case runout by rotating the differential case.





16. Remove the differential case from the rear axle housing and using the Differential Carrier Bearing Step Plate, Differential Carrier Bearing Retaining Ring, Differential Carrier Bearing Collets, Bearing Tube Remover and Bearing Tube Remover Screw, remove the differential bearings.





17. Using the Differential Carrier Bearing Installer, install new differential bearings on the differential case.





18. 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 a new differential case must be installed.





Installation

All vehicles

1. Install the differential ring gear.

1. Place the differential ring gear on the differential case.

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

3. Place the differential assembly on the press bed.

4. Press the ring gear into place with the Differential Carrier Bearing Step Plate and a suitable press.





2. Install the remaining 9 new ring gear bolts.
- Tighten to 63 Nm (46 lb-ft) and then tighten an additional 60 degrees.





3. With the pinion depth set and the pinion installed, place the differential case in the rear axle housing.
- Install a shim on the left side as shown in the illustration.





4. NOTE: The bearing caps must be installed in their original locations and positions.

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

Install the left bearing cap and loosely install the 2 bearing cap bolts.





ELD equipped vehicles

5. Push the ELD coil electrical connector through the differential case and connect the connector to the new adapter.





6. Seat the connector adapter into the differential housing and Install the bolt. Connect the electrical connector.
- Tighten to 15 Nm (133 In lb).





All vehicles

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





8. Install the right side bearing cap and 2 bolts. Tighten the 4 bearing cap bolts.
- Tighten to 118 Nm (87 lb-ft).





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





Measuring backlash

10. Using the Dial Indicator Gauge with Holding Fixture, measure ring gear backlash.
- If a zero backlash condition occurs, go to Zero backlash in this procedure.

- If the backlash is not within specification, go to Backlash not within specification in this procedure.

- If the backlash is within specification, go to Backlash within specification in this procedure. The specification shown is the full allowable range. For the preferred range, refer to Specifications.





Zero backlash

11. If a zero backlash condition occurs, add a 0.50 mm (0.020 in) shim to the RH side and subtract 0.50 mm (0.020 in) from the LH side to allow backlash indication. Check backlash. Repeat Step 8.





Backlash not within specification

12. To increase or decrease backlash, remove the 4 bolts and 2 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.





13. Install the 2 bearing caps and 4 bearing cap bolts.
- Tighten to 118 Nm (87 lb-ft).





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





15. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the backlash.
- If backlash is within specification, go to Backlash within specification in this procedure. If not, repeat Step 8.





Backlash within specification

16. Remove the 2 bearing caps and 4 bolts.
- To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.

- Using the Differential Shim Installer, make sure the differential bearing shims are fully seated and the assembly turns freely.





All vehicles

17. Install the 2 bearing caps and 4 bearing cap bolts.
- Tighten to 118 Nm (87 lb-ft).





18. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, verify the backlash.





19. Install the axle shafts. For additional information, refer to Wheel Hubs and Bearings - Full Floating Axle - Ford Wheel Hubs and Bearings - Full Floating Axle - Ford.

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

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

21. Apply a new, continuous bead of silicone to the differential housing cover as shown.





22. NOTE: The differential cover must be installed within 15 minutes of application of the silicone or new sealant must be applied. If possible, allow an hour before filling with lubricant to make sure the sealant has properly cured.

Install the differential cover and the 12 differential housing cover bolts.

- For stamped steel covers, tighten alternately and evenly to 45 Nm (33 lb-ft).

- For cast aluminium covers, tighten alternately and evenly to 32 Nm (24 lb-ft).

23. NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.

Remove the filler plug, fill the axle to the level shown with axle lubricant and install the filler plug.

- Tighten to 30 Nm (22 lb-ft).