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I changed the ring and pinion on '93 F150 from stupid/cruel 2.73 to 3.27. The case seems too hot after tem minutes at 55 to 60 mph. It has about 130 miles of break in now. It sounds quiet and feels smooth. The specs called for .008 to .012 “ lash, it may be down at .006 or .007”. The question is, does a normal differental get pretty warm to the touch.
Warm, yes. Hot, no. If you touch the cover, and you can't keep your hand there for more than a few seconds, then something is wrong. My guess would be backlash is too tight, or too many shims on carrier bearings. I have never changed a R&P on my own, so I am just guessing as to what the problem is from watching others change them.
You should give the diff a few hundred break-in miles before resuming regular driving. Have you replaced the diff oil yet? The gear oil used during the initial break-in period should be replaced ASAP if it gets hot as it will break down in extreme heat. I broke in my gears by driving for a couple hundred miles, never at highway speeds or longer than 20 mins.
Dustin Siebert
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