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Differential Carrier: Installation

WARNING: This page is about a different car, the 2021 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
  1. NOTE: If the differential housing spreader was removed, install the same to the differential housing.

    Install the Dial indicator gauge with holding fixture, Clutch housing gauge and Differential Carrier spreader. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 205-001 (TOOL-4000-E) Spreader, Differential Carrier., 308-021 (T75L-4201-A) Gauge, Clutch Housing.

    GFD552038Courtesy of FORD MOTOR COMPANY
  2. NOTE: Overspreading may damage the component. Do not spread the differential housing more than 0.762mm (0.030 in).
    NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final dial indicator reading.

    Spread the differential housing to the specification.

    1. Adjust the dial indicator gauge with holding fixture and clutch housing gauge to zero. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 308-021 (T75L-4201-A) Gauge, Clutch Housing.
    2. Tighten the screw until spreading the differential housing to the specification.
    3. Remove the dial indicator gauge with holding fixture and clutch housing gauge.

    GFD552039Courtesy of FORD MOTOR COMPANY
  3. lubricate and install the differential carrier side shims.
    GFD552057Courtesy of FORD MOTOR COMPANY
  4. Install the differential carrier.

    • Position the differential bearing cups on the differential bearings.

    • Lower the differential carrier assembly in place between the differential bearing shims.

    GFD552058Courtesy of FORD MOTOR COMPANY
  5. NOTE: The fixture mounting bolts must have the minimum of 12.7 mm (0.500 In) of thread engagement in the carrier or damage to the component may occur.
    NOTE: Always install the differential bearing caps in their original positions or damage to the component may occur.
    NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.

    • With the differential housing spread to 0.762 mm (0.030 in) maximum. Install the differential caps and the differential cap bolts.

    • Finger tighten the differential bearing cap bolts prior to releasing the carrier spreader. Use Special Service Tool: 205-001 (TOOL-4000-E) Spreader, Differential Carrier., 205-335 (T93P-4000-A) Spreader, Differential Housing (Plate)., 205-368 (T96T-4000-A) Adapter for Differential Housing Spreader.

    GFD552059Courtesy of FORD MOTOR COMPANY
    1. Loosen and Remove the special tools. Use Special Service Tool: 205-001 (TOOL-4000-E) Spreader, Differential Carrier., 205-335 (T93P-4000-A) Spreader, Differential Housing (Plate)., 205-368 (T96T-4000-A) Adapter for Differential Housing Spreader.
    2. Tighten the differential bearing cap bolts.

      Torque: 77 lb.ft (105 Nm)

    GFD552043Courtesy of FORD MOTOR COMPANY
  7. Using the dial indicator, measure the differential ring gear backlash at 4 equally spaced points. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD552035Courtesy of FORD MOTOR COMPANY
  8. NOTE: The fixture mounting bolts must have the minimum of 12.7 mm (0.500 In) of thread engagement in the carrier or damage to the component may occur.

    Remove the axle assembly from the special tool. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.

    GFD552044Courtesy of FORD MOTOR COMPANY
  9. NOTE: Make sure that the mating surface and the bore is free of corrosion and foreign material, avoid particles getting into the bore. Particles might stick on the vent valve assembly and cause damage to vent valve.

    Clean the mating surface of the axle and the axle tube.

    GFD552045Courtesy of FORD MOTOR COMPANY
  10. Apply a new continuous bead of sealant to the differential housing as shown.

    Material

    : Motorcraft® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)

    GFD552046Courtesy of FORD MOTOR COMPANY
  11. Install the axle tube and the axle tube bolts.

    Torque: 54 lb.ft (73 Nm)

    GFD552047Courtesy of FORD MOTOR COMPANY
  12. Install the new inner and outer circlips.
    GFD552048Courtesy of FORD MOTOR COMPANY
  13. NOTE: The axle shaft is not fully seated until the circlip is engaged with the differential side gear.

    Install the axle shaft.

    GFD551994Courtesy of FORD MOTOR COMPANY
  14. NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying the new silicone gasket.

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

    GFD552049Courtesy of FORD MOTOR COMPANY
  15. 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 one hour before filling with lubricant to make sure the silicone sealant has correctly cured.

    Apply a new continuous bead of sealant to the differential housing cover as shown.

    Material

    : Motorcraft® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)

    GFD551741Courtesy of FORD MOTOR COMPANY
  16. Install the differential cover and differential cover bolts.

    Torque: 24 lb.ft (32 Nm)

    GFD552050Courtesy of FORD MOTOR COMPANY
  17. Install the front axle assembly. Refer to: Axle Assembly .
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