Differential Rebuild - Rear

Complete disassembly, inspection, and rebuild of the rear differential including bearing replacement, gear pattern setup, and backlash adjustment for the 2011-2014 Ford F-150 4WD with 5.0L Coyote engine.

Warnings

Tools required

Parts

• Differential rebuild kit (bearings, seals, shims) × 1 — Use OEM specification for 9.75-inch rear axle
• Pinion bearing set × 1 — Use OEM specification
• Pinion seal × 1 — Use OEM specification
• Side bearing set × 1 — Use OEM specification
• Pinion crush sleeve × 1 — Use OEM specification - single use only
• Gear marking compound × 1 — Use OEM specification
• RTV silicone sealant (gray) × 1 — Motorcraft TA-31 or equivalent
• Differential cover gasket or RTV × 1 — Use OEM specification
• Drain plug washer × 1 — Use OEM specification
• Axle shaft seals × 2 — Use OEM specification
• Ring and pinion gear set (if replacing) × 1 — Match original gear ratio

Fluids

• Motorcraft 75W-140 Synthetic Gear Oil — 3 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen rear wheel lug nuts while vehicle is on ground
3. Raise rear of vehicle and support securely on jack stands under frame rails
4. Remove rear wheels and set aside
5. Place drain pan under differential
6. Clean exterior of differential housing with degreaser to prevent contamination during rebuild
7. Mark driveshaft and differential yoke orientation for reassembly alignment

Procedure

1. 1

   Drain differential and remove cover
   Remove drain plug and drain all gear oil into appropriate container. Remove differential cover bolts in crisscross pattern. Carefully pry cover off using pry points, being careful not to damage mating surfaces. Clean all old RTV or gasket material from cover and housing using scraper and brake cleaner.
   Torque spec

   Drain Plug51 Nm (38 lb-ft)

   Cover Bolts42 Nm (31 lb-ft)
2. 2

   Remove driveshaft
   Mark driveshaft flange and pinion yoke position with paint or punch marks for proper reassembly alignment. Remove the four U-joint strap bolts from rear differential yoke. Support driveshaft and slide it rearward out of transmission/transfer case. Do not allow driveshaft to hang by front U-joint.
   Torque spec

   Driveshaft U-Joint Straps20 Nm (15 lb-ft)
3. 3

   Remove axle shafts
   Remove brake calipers and rotors if equipped with disc brakes, or brake drums if equipped with drum brakes. Remove axle shaft retaining bolts from backing plate. Carefully slide axle shafts out of housing. Inspect axle shaft splines and bearing surfaces for wear or damage. Set axles aside in clean area.
4. 4

   Mark and measure carrier bearing caps
   Before removal, use center punch or paint to mark carrier bearing caps and their corresponding housing positions (left/right orientation). Install dial indicator and measure ring gear backlash at 4 points around gear (90-degree intervals). Record all measurements for reference during reassembly. Note pattern of any existing shims behind carrier bearings.
5. 5

   Remove differential carrier assembly
   Remove carrier bearing cap bolts. Carefully pry carrier bearing caps off using appropriate tools. Note position and thickness of any shims behind carrier bearings - keep shims organized by side. Use pry bars to carefully lift carrier assembly with ring gear out of housing. Place carrier assembly on clean workbench.
   ⚠Carrier assembly is heavy (40-50 lbs). Get assistance or use lifting device to prevent dropping.
6. 6

   Remove pinion gear assembly
   Mark pinion nut position relative to pinion shaft threads for reference. Use pinion holding tool to prevent rotation and remove pinion nut. Use appropriate puller to remove pinion yoke/flange. Tap pinion shaft rearward out of housing - catch pinion and bearings as they come free. Remove pinion rear bearing, crush sleeve, and front bearing from pinion shaft if they don't come out with housing.
   ℹ️Count and record number of threads showing above pinion nut before removal for initial reassembly reference.
7. 7

   Remove pinion bearing races and seals
   Use bearing race puller or drift punch to remove front and rear pinion bearing races from housing. Drive out pinion seal from housing front. Remove rear pinion bearing race. Inspect housing bore for any damage, scoring, or excessive wear that would prevent proper bearing seating.
8. 8

   Disassemble and inspect carrier
   Remove ring gear bolts and separate ring gear from carrier if replacing gears. Press or pull carrier bearings off carrier. Thoroughly inspect all components: check ring and pinion teeth for pitting, scoring, or excessive wear; inspect carrier and pinion for cracks; measure bearing races and rollers for wear. Determine which components require replacement.
9. 9

   Install new pinion bearings and races
   Using hydraulic press or bearing driver, install new front and rear pinion bearing races into housing until fully seated. Ensure races are square and fully bottomed in bores. Press new rear pinion bearing onto pinion shaft using appropriate driver. Install correct shim pack on pinion (refer to marking on new gear set or calculate based on old shim pack and pinion depth variance markings).
   ⚠Pinion depth is critical. Use pinion depth variance markings stamped on gear head and face to determine correct shim thickness.
10. 10

    Set pinion bearing preload
    Install new pinion seal in housing using seal driver. Lubricate seal lip with gear oil. Install pinion with rear bearing into housing. Install new crush sleeve, front bearing, pinion yoke, and washer. Install new pinion nut. Using pinion holding tool and inch-pound torque wrench, tighten pinion nut gradually while rotating pinion to seat bearings. Measure rotating torque - target is 16-29 inch-pounds for new bearings. If preload is exceeded, crush sleeve must be replaced and process restarted.
    ⚠️Never loosen pinion nut to reduce preload. If preload is exceeded, entire crush sleeve must be replaced and assembly restarted.
    ⚠Tighten pinion nut in small increments (1/8 turn) checking preload frequently. It is easy to overtighten.
11. 11

    Assemble carrier with ring gear
    If installing new ring gear, clean all thread lock from old bolts or use new bolts per manufacturer specification. Install ring gear on carrier in correct orientation. Apply thread locker to ring gear bolts and tighten in star pattern to manufacturer specification. Press or drive new carrier bearings onto carrier until fully seated against shoulders.
12. 12

    Install carrier and set backlash
    Install carrier assembly into housing with original shim pack as starting point. Install bearing caps in correct orientation (reference marks made during disassembly). Tighten bearing cap bolts to secure carrier. Install dial indicator to measure ring gear backlash. Adjust shims side-to-side to achieve proper backlash (0.003-0.009 inches, target 0.006 inches) while maintaining carrier bearing preload. Thicker shim on left side increases backlash; thicker on right side decreases backlash.
    ℹ️Shim changes should be equal and opposite (e.g., add 0.010 to left, remove 0.010 from right) to maintain bearing preload while adjusting backlash.
13. 13

    Check gear tooth contact pattern
    Apply gear marking compound to 6-8 teeth on ring gear in 3 locations around circumference. Rotate pinion in both directions while applying slight load to mark gear teeth. Inspect contact pattern on drive and coast sides of teeth. Proper pattern should be centered on tooth face. Adjust pinion depth (shims behind pinion) if pattern is too high or low on tooth. Adjust backlash if pattern is too far toward toe or heel. Recheck pattern after each adjustment until correct.
    ⚠Incorrect gear pattern will cause noise and premature gear failure. Take time to achieve proper contact pattern across entire tooth face.
14. 14

    Final assembly and seal installation
    Once backlash and gear pattern are correct, remove carrier bearing caps and apply small amount of RTV sealant to cap mating surfaces. Reinstall caps and torque cap bolts to specification. Install new axle shaft seals in housing ends using seal driver. Ensure seals are square and fully seated. Clean all mating surfaces thoroughly with brake cleaner.
15. 15

    Install differential cover and refill
    Apply 1/4-inch bead of RTV sealant to differential cover flange or install new gasket per manufacturer specification. Install cover and tighten bolts in crisscross pattern. Allow RTV to cure for 15-30 minutes before filling. Install new drain plug washer and reinstall drain plug. Remove fill plug and add Motorcraft 75W-140 synthetic gear oil until it reaches bottom of fill hole (approximately 3 quarts). Reinstall fill plug with new washer if applicable.
    ℹ️If equipped with limited slip differential, add appropriate friction modifier additive per manufacturer specification.
    Torque spec

    Cover Bolts42 Nm (31 lb-ft)

    Drain Plug51 Nm (38 lb-ft)

    Fill Plug51 Nm (38 lb-ft)

Reassembly

1. Install axle shafts into housing, ensuring splines engage properly with differential side gears
2. Install axle shaft retaining bolts and torque to specification
3. Reinstall brake components (drums or rotors and calipers) and adjust if necessary
4. Align driveshaft marks made during disassembly and install driveshaft to pinion yoke
5. Install U-joint strap bolts and torque evenly in crisscross pattern
6. Install wheels and hand-tighten lug nuts
7. Lower vehicle to ground and torque wheel lug nuts in star pattern
8. Test drive vehicle and listen for any abnormal noises from differential

Verification

• Check for any fluid leaks around differential cover, pinion seal, and axle seals after initial test drive
• Listen for abnormal whining, howling, or clunking noises during test drive - noise indicates improper setup
• Verify smooth operation during acceleration, deceleration, and turning
• Recheck fluid level after 50-100 miles of driving and top off if necessary
• Monitor differential temperature during first several drives - excessive heat indicates problem with setup
• After 500 miles, drain and inspect fluid for metal particles which would indicate gear wear from improper setup

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