Differential Case Runout Check

WARNING: This page is about a different car, the 2014 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL DESCRIPTION

	2 Jaw Puller 205-D072 (D97L-4221-A) or equivalent
	Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C)
	Installer, Differential Side Bearing 205-010 (T57L-4221-A2)
	Spreader, Differential Carrier 205-001 (TOOL-4000-E)
	Step Plate 205-D061 (D83T-4205-C2)

Remove the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .
NOTE: Use a drift punch to separate the ring gear from the differential case.

Remove and discard the 10 bolts. Remove the ring gear.

Fig 1: Removing Differential Ring Gear
Courtesy of FORD MOTOR CO.
NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating bearing overheating or failure.

NOTE: It may be necessary to use the Differential Carrier Spreader to carry out this step.

Install the differential case with the bearing cups and all the shims in the housing.
1. Position the differential case with the bearing cups and shims in their original location.
2. Install the 2 bearing caps.
3. Install the 4 bolts.
  - Tighten to 105 Nm (77 lb-ft).
4. Rotate the differential case to make sure the bearings have seated correctly.
  
  Fig 2: Identifying Differential Case And Bearings
  Courtesy of FORD MOTOR CO.
Install the Dial Indicator Gauge with Holding Fixture.

Fig 3: Identifying Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.
Rotate the differential case and check the differential case runout using the Dial Indicator Gauge with Holding Fixture.
- If the runout does not exceed the specification, install a new ring gear and pinion.
- If runout exceeds the specification, the ring gear is true and the condition is due to differential case/differential bearing damage.
  - Inspect the differential bearings and the differential case. Always install new differential bearings when installing a new differential case, or if a bearing condition is questionable.
    
    Fig 4: Checking Differential Case Runout Using Dial Indicator Gauge
    Courtesy of FORD MOTOR CO.
Remove the bearing caps and the differential case with the bearing cups and shims from the housing.
If necessary, using the 2 Jaw Puller and Step Plate, remove the differential bearings.

Fig 5: Removing Differential Bearing Using Jaw Puller And Step Plate
Courtesy of FORD MOTOR CO.
NOTE: Press against the differential bearing inner cone only or damage to the component may occur.

Install the new differential bearings.
1. Position the appropriate differential bearing (RH or LH).
2. Using a suitable press and the Differential Side Bearing Installer, install the differential bearing.
  - Repeat the steps for the other differential bearing.
    
    Fig 6: Installing Differential Bearings Using Press
    Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to use the Differential Carrier Spreader to carry out this step.

NOTE: Recheck the flange runout.

Install the differential case with the bearing cups and the shims in the housing.
1. Position the differential case with the bearing cups and shims in their original locations.
2. Install the 2 bearing caps.
3. Install the 4 bolts.
  - Tighten to 105 Nm (77 lb-ft).
4. Rotate the differential case to make sure the bearings have seated correctly.
  
  Fig 7: Identifying Differential Case And Bearings
  Courtesy of FORD MOTOR CO.
Install the Dial Indicator Gauge with Holding Fixture.

Fig 8: Identifying Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.
NOTE: If the runout is still excessive, install a new differential case.

Using the Dial Indicator Gauge with Holding Fixture, check the runout with the new differential bearings. If the runout does not exceed the specification, use the new differential bearings for assembly.

Fig 9: Checking Differential Case Runout Using Dial Indicator Gauge
Courtesy of FORD MOTOR CO.
Remove the 4 bolts.

Fig 10: Locating Bearing Caps Mounting Bolts
Courtesy of FORD MOTOR CO.
Remove the differential case with the bearing cups and the shims from the housing.
1. Remove the 2 bearing caps.
2. Remove the differential case with the bearing cups and the shims from the housing.
  
  Fig 11: Identifying Differential Case And Bearing Caps
  Courtesy of FORD MOTOR CO.
Install the differential ring gear.
1. Place the differential ring gear on the differential assembly.
2. Hand-start 3 new ring gear bolts to align the holes in the differential ring gear and the differential assembly.
3. Place the differential carrier and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
4. Press the differential ring gear into place.
  
  Fig 12: Installing Differential Ring Gear Using Tool
  Courtesy of FORD MOTOR CO.
Install the 10 new ring gear bolts.
- Tighten to 128 Nm (95 lb-ft).
  
  Fig 13: Identifying Differential Ring Gear Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .