Removal and Installation

Special Tools:

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

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

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

Position the Dial Indicator with Bracketry, and inspect ring gear backlash and ring gear backface runout.

6. 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.

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

8. 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.

9. Remove the ring gear bolts.

10. CAUTION: Care should betaken not to damage the ring bolt hole threads.

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.

11. 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 differential bearing caps.
3 Install the differential bearing cap bolts.

12. NOTE: Rotate the differential case to make sure the differential bearings are properly 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 not damaged, replace both the differential case and the differential bearings.

Measure the differential case runout using the Dial Indicator with Bracketry and by rotating the differential case.

13. Remove the differential case from the rear axle housing, and prepare to remove the differential bearings.
1 Position the Step Plate.
2 Position the Forcing Screw and the Remover and Replacer Tube.
3 Position the Collet Halves.

14. Position the Side Carrier Bearing Retaining Ring.

15. Using two wrenches, remove the differential bearing.
^ Repeat the procedure for the other differential bearing.

16. Use the Differential Side Bearing Replacer to install the new differential bearings on the differential case.

17. 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 replaced.

Installation

1. 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-1 9554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring; gear bolts.

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.

4. CAUTION: The bearing caps must toe 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 bearing cap bolts.

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

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

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

8. Use the Dial Indicator with Bracketry to measure ring gear backlash.
^ If the backlash is within specification, go to Step 14. The specification shown is the full allowable range.
^ If a zero backlash condition occurs, go to Step 9.
^ If the backlash is not within specification, go to Step 10.

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

10. 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.

11. Install the bearing caps and bearing cap bolts.

12. Rotate the differential several times to make sure the differential bearings are properly seated.

13. Use the Dial Indicator with Bracketry to recheck the backlash.
^ If backlash is within specification, go to Step 14. If not, repeat Step 8.
^ The specification shown is the full allowable range.

14. 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.
^ Use a Shim Driver to ensure the differential bearing shims are fully seated and the assembly turns freely.

15. Install the bearing caps and bearing cap bolts.

16. Use the Dial Indicator with Bracketry to verify the backlash.
^ The specification shown is the full allowable range.

17. Install the axle shafts.
18. Install the axle housing cover, and refill the rear axle with specified lubricant.
19. Install the driveshaft.