Differential Case Runout Check

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-1016Installer, Differential BearingTKIT-2014D-ROW2, TKIT-2014D-FL_ROW
Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W)Handle
Courtesy of FORD MOTOR COMPANY	205-D061 (D83T-4205-C2)Step Plate
Dial Indicator
Three Leg Puller
Punch
Copper Hammer

Check 

1. Remove the differential. Refer to: Differential Carrier .
2. Remove and discard the ring gear bolts.

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3. NOTE: Care should be taken not to damage the differential ring gear bolt hole threads.

   Using the general equipments, remove the ring gear. Use the General Equipment: PunchUse the General Equipment: Copper Hammer

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4. Install the Differential carrier, differential carrier bearing cups and differential bearing preload shims.

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5. Install the differential bearing caps and bolts. Align the differential bearing caps in there original location.

   Torque: 94 lb.ft (128 Nm)

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6. Rotate the differential carrier to make sure the bearings have seated correctly.

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7. Using the dial indicator, rotate the differential carrier and measure the differential carrier runout.
   • If the runout does not exceed the specification, install a new ring gear and pinion. Use the General Equipment: Dial Indicator
   • If runout exceeds the specification, the ring gear is true and the condition is due to differential carrier/differential bearing damage.
   • Inspect the differential bearings and the differential carrier. Always install new differential bearings when installing a new differential carrier, or if a bearing condition is questionable.

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8. Remove the bolts and the differential bearing caps.

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9. Remove the differential carrier, differential bearing cups, and differential bearing preload shims.

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10. NOTE: If necessary.

    Using the special tool and the general equipment, remove and discard the differential bearings. Use Special Service Tool: 205-D061 (D83T-4205-C2) Step Plate. Use the General Equipment: Three Leg Puller

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11. Using the special tools, install the new differential bearings. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-1016 Installer, Differential Bearing.

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12. Install the Differential carrier, differential carrier bearing cups and differential bearing preload shims.

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13. Install the differential bearing caps and bolts. Align the differential bearing caps in there original location.

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14. Rotate the differential carrier to make sure the bearings have seated correctly.

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15. NOTE: If the runout is still excessive, install a new differential case.

    Using the dial indicator, rotate the differential carrier and measure the differential carrier runout. Use the General Equipment: Dial Indicator

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16. Remove the bolts and the differential bearing caps.

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17. Remove the differential carrier, differential bearing cups, and differential bearing preload shims.

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18. NOTE: Tighten the ring gear bolts in a cross pattern.

    Install the ring gear and the new ring gear bolts.

    Torque: 94 lb.ft (128 Nm)

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19. Install the differential carrier. Refer to: Differential Carrier .