Differential Case and Ring Gear - Conventional
Differential Case and Ring Gear - ConventionalSpecial Tool(s):
Material:
Disassembly
1. Remove the differential carrier.
2. Remove 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. NOTE: The anti-lock ring cannot be reused once removed.
If necessary, remove the anti-lock ring.
5. If necessary, remove the differential bearings with the special tools.
6. Remove the differential pinion shaft lock bolt and the differential pinion shaft.
7. Rotate and remove the differential pinion gears and differential pinion gear thrust washers.
8. Remove the differential side gears and the differential side gear thrust washers.
Assembly
1. Position the differential side gear thrust washers on the differential side gears.
^ Lubricate the differential side gear thrust washers and the differential side gear journals with axle lubricant.
2. Position the differential side gears.
3. Assemble the differential pinion gear thrust washers and the differential pinion gears.
^ Lubricate the washers and gears with rear axle lubricant.
4. Engage the differential pinion gears opposite the differential side gears.
5. Rotate the differential pinion gears to align the differential pinion shaft bore.
6. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.
7. If removed, use the special tool to install the differential bearings.
8. Press the new anti-lock ring (if removed) and the differential ring gear on the differential case.
9. Install the 12 differential ring gear bolts.
^ Apply stud and bearing mount to the differential ring gear bolts.
^ Tighten to 150 Nm (111 ft. lbs.).
10. Install the differential assembly in the axle housing.
11. NOTE: Install the differential bearing shims with the chamfer facing outboard.
Install a differential bearing shim on the LH side.
12. CAUTION: 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 differential bearing cap bolts.
13. 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.
14. Install the RH side differential bearing cap and tighten the LH side and RH side differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).
15. Rotate the differential assembly to make sure it rotates freely.
16. NOTE: If ring gear backlash is within specification, go to Step 21.
NOTE: Specification shown is the maximum ring gear backlash allowable.
Using the special tools, measure ring gear backlash.
^ Turn the ring gear without turning the pinion gear and record the measurement.
17. 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.
18. 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 and a thinner differential bearing shim of the same thickness change.
19. Rotate the differential assembly several times to make sure the differential bearings are seated.
20. Using the special tools, recheck the ring gear backlash.
21. Remove the differential bearing cap bolts and differential bearing caps.
22. 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 special tool, install the differential bearing shims.
23. Install the differential bearing caps and differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).
24. Apply Motorcraft High Contrast Hypoid Gear Marking Compound and rotate the differential assembly 5 complete revolutions.
25. Verify an acceptable pattern check.
26. CAUTION: 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. 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.
27. Install the axle shafts.
28. Apply a new, continuous bead of sealant to the differential housing cover.
29. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has correctly cured.
Install the differential housing cover and the differential housing cover bolts.
^ Tighten to 45 Nm (33 ft. lbs.).
30. 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.
Fill the axle to the level shown with axle lubricant and install the filler plug.
^ Tighten to 30 Nm (22 ft. lbs.).
