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Disassembly And Assembly: Axle: Assembly

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  1. NOTE: Do not omit the pinion bearing oil baffle; bearing failure may result.

    If removed, position the baffle on the Drive Carrier Bearings Installer.

    Fig 1: Positioning Drive Pinion Bearing Oil Baffle On Differential Carrier Bearing Installer
    G06125467Courtesy of FORD MOTOR CO.
  2. Using the Drive Carrier Bearings Installer, install the baffle.
    Fig 2: Installing Drive Pinion Bearing Oil Baffle Using Differential Carrier Bearing Installer
    G06125468Courtesy of FORD MOTOR CO.
  3. NOTE: Always install new pinion bearings when installing new pinion bearing cups.

    Lightly oil the new pinion bearing cups and pinion bearings with front axle lubricant.

  4. Using the Drive Pinion Bearing Cup Installer, install the bearing cups.
    Fig 3: Installing Drive Pinion Bearing Cups Using Drive Pinion Bearing Cup Installer
    G06125469Courtesy of FORD MOTOR CO.
  5. NOTE: The pinion bearings assembled in this procedure step must be used at final assembly.

    Assemble and position the Adapters and the pinion bearings in the carrier housing.

    1. Position the screw adapter.
    2. Position the aligning adapter.
    3. Position the pinion bearing.
    4. Position the gauge disc adapter.
    5. Position the gauge block adapter.
    6. Position the pinion bearing.
    7. Thread on the handle adapter.
      Fig 4: Positioning Drive Pinion Bearing Installation Adapter
      G06125470Courtesy of FORD MOTOR CO.
  6. NOTE: This step duplicates final pinion bearing preload.

    Tighten the Adapter to simulate bearing preload.

    • Tighten to 2.2 Nm (20 lb-in).
      Fig 5: Checking Differential Pinion Bearing Preload Using Tool
      G06125144Courtesy of FORD MOTOR CO.
  7. NOTE: Offset the gauge block adapter to obtain an accurate reading.

    Rotate the gauge block Adapter several half-turns to make sure the pinion bearings seat correctly and position the gauge block adapter.

    Fig 6: Checking Drive Pinion Bearings Installation Position Using Adapter
    G06125472Courtesy of FORD MOTOR CO.
  8. Install the Drive Pinion Gauge Tube.
    1. Position the Drive Pinion Gauge Tube.
    2. Install the 2 differential bearing caps.
    3. Install the 4 bolts.
      • Tighten to 105 Nm (77 lb-ft).
        Fig 7: Positioning Drive Pinion Gauge Tube
        G06125473Courtesy of FORD MOTOR CO.
  9. NOTE: Use only flat, clean drive pinion bearing adjustment shims.
    NOTE: Do not attempt to force the shim between the gauge block adapter and the gauge tube adapter. A slight drag indicates correct shim selection.

    Use a drive pinion bearing adjustment shim as a gauge for shim selection.

    • Check the adjustment shim thickness between the gauge block adapter and the gauge tube adapter.
    • After determining the correct shim thickness, remove the Drive Pinion Gauge Tube.
      Fig 8: Removing Drive Pinion Gauge Tube
      G06125675Courtesy of FORD MOTOR CO.
  10. NOTE: The same pinion bearings from the previous steps must be used.

    Install the pinion bearing.

    • Place the drive pinion bearing adjustment shim on the pinion gear.
    • Using a suitable press and the Drive Pinion Bearing Cone Installer, press the pinion bearing until it is firmly seated on the pinion gear.
      Fig 9: Installing Inner Drive Pinion Bearing Using Tool
      G06125476Courtesy of FORD MOTOR CO.
  11. Install the pinion gear.
    G09378611
  12. Install the new collapsible spacer.
    G09378612
  13. Install the outer pinion bearing.
    G09378613
  14. Install the pinion oil slinger.
    G09378614
  15. NOTE: Coat the lips of the pinion seal with front axle lubricant.

    Place the pinion seal on the Drive Pinion Oil Seal Installer.

  16. Place the Drive Pinion Oil Seal Installer and seal in the pinion seal bore and drive the seal into place.
    Fig 10: Installing Drive Pinion Seal Using Drive Pinion Oil Seal Installer
    G07403951Courtesy of FORD MOTOR CO.
  17. Lightly lubricate the pinion gear splines with front axle lubricant.
  18. Position the drive pinion in the housing.
    Fig 11: Positioning Drive Pinion Gear In Axle Housing
    G06125222Courtesy of FORD MOTOR CO.
  19. NOTE: Never install the drive pinion U-joint flange with a hammer or power tools.
    NOTE: Disregard the scribe marks if installing a new flange.

    Align the index marks and position the U-joint flange on the drive pinion.

  20. Using the Drive Pinion Flange Installer, install the drive pinion U-joint flange.
    Fig 12: Installing Drive Pinion Flange Using Installer
    G06125384Courtesy of FORD MOTOR CO.
  21. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.
  22. NOTE: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut or damage to the component may occur.

    Install the Drive Pinion Flange Holding Fixture and tighten the pinion nut. Refer to the TORQUE SPECIFICATIONS  in the Specifications portion of this article.

    • Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (lb-in) torque wrench.
      Fig 13: Tightening Pinion Nut Using Tool
      G06125457Courtesy of FORD MOTOR CO.
      Fig 14: Checking Pinion Bearing Preload Torque Using Torque Wrench
      G06125378Courtesy of FORD MOTOR CO.
  23. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface.
    Fig 15: Locating Ring Gear Mounting Surface Inspection Area
    G06125686Courtesy of FORD MOTOR CO.
  24. Install the differential ring gear.
    1. Place the differential ring gear on the differential assembly.
    2. Hand-start 3 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 gear teeth facing downward.
    4. Press the differential ring gear into place.
      Fig 16: Installing Differential Ring Gear
      G06125313Courtesy of FORD MOTOR CO.
  25. Install the remaining new bolts.
    • Tighten to 128 Nm (95 lb-ft).
      Fig 17: Locating Differential Ring Gear Mounting Bolts
      G06125372Courtesy of FORD MOTOR CO.
  26. NOTE: Press against the bearing inner core only.

    Using a suitable press and the Differential Side Bearing Installer, install the 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 procedure for the other differential bearing.
        Fig 18: Pressing Differential Bearing On Differential Carrier
        G06125487Courtesy of FORD MOTOR CO.
  27. Install the differential carrier.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential carrier in place.
      Fig 19: Installing Differential Carrier
      G06125490Courtesy of FORD MOTOR CO.
  28. Install a differential bearing shim of the thickness shown on the LH side of the differential bearing.
    Fig 20: Identifying Differential Bearing Shim
    G06125491Courtesy of FORD MOTOR CO.
  29. NOTE: Apply pressure to the left side to make sure the left bearing cup is seated.

    Install the left bearing cap and loosely install the 2 bearing cap bolts.

    Fig 21: Locating Bearing Cap And Mounting Bolts
    G06125492Courtesy of FORD MOTOR CO.
  30. Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.
    Fig 22: Installing Differential Bearing Shim
    G06125493Courtesy of FORD MOTOR CO.
  31. Install the right bearing cap and 2 bolts.
  32. Tighten the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
  33. Rotate the differential carrier to make sure it turns freely.
  34. Install the Dial Indicator Gauge with Holding Fixture.
    Fig 23: Installing Dial Indicator Gauge With Holding Fixture
    G06125494Courtesy of FORD MOTOR CO.
  35. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the ring gear backlash at 4 places to obtain a consistent reading.
    Fig 24: Checking Ring Gear Backlash Using Dial Indicator Gauge
    G06125695Courtesy of FORD MOTOR CO.
  36. NOTE: If the backlash is not within the specifications, correct it by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.

    To increase the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown below.

    Fig 25: Locating Differential Bearing Shim (To Increase Backlash)
    G06125696Courtesy of FORD MOTOR CO.
  37. To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown below.
    Fig 26: Locating Differential Bearing Shim (To Decrease Backlash)
    G06125697Courtesy of FORD MOTOR CO.
  38. Select the appropriate shim by the thickness or the stripe color.
    Backlash Change Required Thickness Change Required
    mm Inch mm Inch
    0.025 0.001 0.050 0.002
    0.050 0.002 0.050 0.002
    0.076 0.003 0.101 0.004
    0.101 0.004 0.152 0.006
    0.127 0.005 0.152 0.006
    0.152 0.006 0.203 0.008
    0.177 0.007 0.254 0.010
    0.203 0.008 0.254 0.010
    0.228 0.009 0.304 0.012
    0.254 0.010 0.355 0.014
    0.279 0.011 0.355 0.014
    0.304 0.012 0.406 0.016
    0.330 0.013 0.457 0.018
    0.335 0.014 0.457 0.018
    0.381 0.015 0.508 0.020
    DIFFERENTIAL SHIM SIZE CHART

    Stripes/Color mm Inch
    2 - C-COAL 7.7978-7.8105 0.3070-0.3075
    1 - C-COAL 7.7470-7.7597 0.3050-0.3055
    5 - BLU 7.6962-7.7089 0.3030-0.3035
    4 - BLU 7.6454-7.6581 0.3010-0.3015
    3 - BLU 7.5946-7.6073 0.2990-0.2995
    2 - BLU 7.5458-7.5565 0.2970-0.2975
    1 - BLU 7.4930-7.5050 0.2950-0.2955
    5 - PINK 7.4422-7.4549 0.2930-0.2935
    4 - PINK 7.3914-7.4041 0.2910-0.2915
    3 - PINK 7.3406-7.3533 0.2890-0.2895
    2 - PINK 7.2898-7.3025 0.2870-0.2875
    1 - PINK 7.2390-7.2517 0.2850-0.2855
    5 - GRN 7.1882-7.2009 0.2830-0.2835
    4 - GRN 7.1374-7.1501 0.2810-0.2815
    3 - GRN 7.0866-7.0993 0.2790-0.2795
    2 - GRN 7.0358-7.0485 0.2770-0.2775
    1 - GRN 6.9850-6.9977 0.2750-0.2755
    5 - WH 6.9342-6.9469 0.2730-0.2735
    4 - WH 6.8834-6.8961 0.2710-0.2715
    3 - WH 6.8326-6.8453 0.2690-0.2695
    2 - WH 6.7818-6.7945 0.2670-0.2675
    1 - WH 6.7310-6.7437 0.2650-0.2655
    5 - YEL 6.6802-6.6929 0.2630-0.2635
    4 - YEL 6.6294-6.6421 0.2610-0.2615
    3 - YEL 6.5786-6.5913 0.2590-0.2595
    2 - YEL 6.5278-6.5405 0.2570-0.2575
    1 - YEL 6.4770-6.4897 0.2550-0.2555
    5 - ORNG 6.4262-6.4389 0.2530-0.2535
    4 - ORNG 6.3754-6.3881 0.2510-0.2515
    3 - ORNG 6.3246-6.3373 0.2490-0.2495
    2 - ORNG 6.2738-6.2865 0.2470-0.2475
    1 - ORNG 6.2223-6.2357 0.2450-0.2455
    2 - RED 6.1722-6.1849 0.2430-0.2335
    1 - RED 6.1214-6.1341 0.2410-0.2415
  39. Remove the 4 differential bearing cap bolts.
    • Remove the differential carrier.
  40. Measure the thickness of the selected right and left bearing shims.
  41. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 in).
  42. Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier Spreader.
    Fig 27: Identifying Dial Indicator Gauge, Holding Fixture, Clutch Housing Gauge And Differential Carrier Spreader
    G06125453Courtesy of FORD MOTOR CO.
  43. NOTE: Overspreading may damage the differential housing.
    NOTE: Tighten and loosen the differential carrier spreader adapters to normalize the housing adapters prior to taking the final Dial Indicator reading.

    Spread the differential housing to the specification.

    1. Adjust the Dial Indicator Gauge to zero.
    2. Tighten the screw until spreading the differential housing to the specifications.
    3. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
      Fig 28: Spreading Differential Housing Using Dial Indicator Gauge
      G06125454Courtesy of FORD MOTOR CO.
  44. NOTE: To avoid galling the case, insert the shims with a light coating of grease before installing the differential carrier.

    Place the differential bearing shims in the differential housing.

    Fig 29: Locating Differential Bearing Shims In Differential Housing
    G06125498Courtesy of FORD MOTOR CO.
  45. Install the differential carrier.
    1. Position the 2 differential bearing cups on the differential bearings.
    2. Lower the differential carrier in place between the differential bearing shims.
      Fig 30: Installing Differential Carrier
      G06125490Courtesy of FORD MOTOR CO.
  46. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the Differential Carrier Spreader.

    Install the 2 differential bearing caps and 4 bolts in their original location.

    Fig 31: Locating Differential Bearing Cap Mounting Bolts
    G06125500Courtesy of FORD MOTOR CO.
  47. Loosen and remove the Differential Carrier Spreader.
    Fig 32: Removing Differential Carrier Spreader
    G06125501Courtesy of FORD MOTOR CO.
  48. Install the Dial Indicator Gauge with Holding Fixture at the 12 o'clock position.
    Fig 33: Installing Dial Indicator Gauge With Holding Fixture
    G06125494Courtesy of FORD MOTOR CO.
  49. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the ring gear backlash.
    Fig 34: Checking Ring Gear Backlash Using Dial Indicator Gauge
    G06125695Courtesy of FORD MOTOR CO.
  50. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  51. Verify an acceptable pattern check. Refer to DIAGNOSIS AND TESTING .
  52. Assemble the axle housing tube.
    • Align the bolt holes and position the axle tube.
    • Position the axle identification tag.
    • Install the 4 bolts.
      • Tighten to 73 Nm (54 lb-ft).
        Fig 35: Installing Axle Housing Tube
        G06125504Courtesy of FORD MOTOR CO.
  53. Install a new stub shaft seal. Refer to STUB SHAFT PILOT BEARING AND SEAL .
  54. Install a new circlip on the intermediate shaft end.
    Fig 36: Locating Intermediate Shaft End Circlip
    G09538613Courtesy of FORD MOTOR CO.
  55. Insert the intermediate shaft and engage the circlip with the side gears.
  56. Remove the axle assembly from the Holding Fixture and place it on the bench.
  57. NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying the new silicone gasket.
    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 continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface as shown in the illustration.

    • Use silicone gasket and sealant.
      Fig 37: Locating Sealant Applying Area On Differential Housing Cover Mounting Surface
      G06125506Courtesy of FORD MOTOR CO.
  58. Install the differential housing cover and the 10 cover bolts.
    • Tighten to 32 Nm (24 lb-ft).
      Fig 38: Identifying Differential Housing Cover And Mounting Bolt
      G06125448Courtesy of FORD MOTOR CO.
  59. Install the axle assembly. Refer to AXLE ASSEMBLY .
  60. Remove the fill plug and fill the axle assembly with the specified type and amount of lubricant.
    • Tighten the fill plug to 25 Nm (18 lb-ft).
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