Component Disassembly & Reassembly: Differential: Disassembly

1. Remove rear bearing cup and shims from case; use Stator And Sprocket Bearing Remover (T86P-70043-A), Disc Brake Piston Remover (T73L-2196-A) and Slide Hammer (T50T-100-A). Install front bearing cup into converter housing using Driver Handle And Differential Bearing Cup Replacer (T88C-77000-FH).
2. Insert differential into converter housing. Place 6 collars of Shim Selector Set (T87C-77000-J) on converter housing. Install rear bearing cup over differential bearing. Using Shim Selection Gauge (T88C-77000-C1) on output gear, turn 2 halves of gauge to eliminate any gap.
3. Install transaxle case. Tighten to 27-38 ft. lbs. (36-52 N.m). Using shim selection kit pins, unthread gauge halves until all free play is removed and bearing is seated. Thread gauge halves back together.
4. Using a Differential Rotator (T88C-77000L) and INCH-pound torque wrench, measure drag on differential bearing. Read preload when differentials starts turning. Using pins of Shim Selector Set (T87C-77000-J), turn gauge until a reading of 4.3 INCH lbs. (.5 N.m) is obtained.
5. Using a feeler gauge, measure gap between 2 halves in 4 spots at 90-degree intervals. See Fig 1 . Use largest measurement, and add .008" (.20 mm). Select no more than 3 shims to maintain clearance. Shims are available in .004-.040" (.10-1.00 mm) thicknesses.

Fig 1: Measuring Differential Preload

Courtesy of FORD MOTOR CO.