Disassembly And Assembly: Axle: Assembly

Assembly, Differential Case and Ring Gear-Traction-Lok® 

1. Prelubricate each steel clutch plate and soak all friction plates with 118 ml (4 ounces) of friction modifier for at least 15 minutes.
   Fig 1: Lubricating Steel Clutch Plates

   Courtesy of FORD MOTOR CO.
NOTE: Do not mix the differential clutch packs or shims from one side with the opposing side.
Fig 2: Assembling Differential Clutch Packs On Side Gears
Courtesy of FORD MOTOR CO.
2. Assemble the differential clutch packs (without the shims or Belleville springs) on the respective side gears.
3. Clamp the bolt head of the special tool in a vise. Install the differential clutch pack and the differential side gear (without the shims or Belleville spring) on the gauge.
   Fig 3: Installing Differential Clutch Pack And Differential Side Gear

   Courtesy of FORD MOTOR CO.
4. Position the special tool on top of the differential clutch pack.
   Fig 4: Positioning Special Tool On Top Of Differential Clutch Pack

   Courtesy of FORD MOTOR CO.
5. Install the special tool over the disc and differential clutch pack.
   Fig 5: Installing Special Tool Over Disc And Differential Clutch Pack

   Courtesy of FORD MOTOR CO.
6. Install the nut over the top and base stud.
   Fig 6: Installing Nut Over Top And Base Stud

   Courtesy of FORD MOTOR CO.
NOTE: A maximum of two shims can be used on each clutch pack.
Fig 7: Shims Specifications
Courtesy of FORD MOTOR CO.
Fig 8: Selecting Correct Shim
Courtesy of FORD MOTOR CO.
7. Select and insert the thickest feeler gauge blade that will enter between the tool and the differential clutch pack. Subtract 0.010 inch from the reading to obtain the thickness of the new clutch shim. Select the correct shim and remove the special tool.
NOTE: The concave side of the Belleville spring must face up and against the thrust face of the differential case.
Fig 9: Placing Shim And Belleville Spring On Differential Clutch Pack
Courtesy of FORD MOTOR CO.
8. Place the shim and the Belleville spring on the differential clutch pack.
9. Insert the differential clutch packs with the shims and Belleville springs and differential side gears into the differential case.
   Fig 10: Inserting Differential Clutch Packs With Shims And Belleville Springs

   Courtesy of FORD MOTOR CO.
NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.
10. Assemble the special tool in the differential case.
    1. Position the special tool in the bottom side gear bore.
    2. Position the special tool in the top side gear bore and hold it in place.
    3. Install the special tool and tighten it two turns after it contacts the bottom step plate.
       Fig 11: Positioning Special Tool In Bottom Side Gear Bore

       Courtesy of FORD MOTOR CO.
NOTE: Coat both sides of the differential pinion thrust washers with rear axle lubricant.
Fig 12: Positioning Differential Pinion Gears And Thrust Washers In Differential Case Window
Courtesy of FORD MOTOR CO.
11. Position the differential pinion gears and thrust washers in the differential case window so they mesh with the differential side gear teeth.
NOTE: It may be necessary to loosen or tighten the special tool forcing screw to allow the differential side gears to rotate.
Fig 13: Inserting Special Tool Into Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
12. Insert the special tool into the pinion shaft bore and turn the differential case. This will move the differential side gears and position them in the differential case. Rotate the differential case until the pinion mating shaft holes are aligned with the differential pinion gears.
13. Loosen the special tool forcing screw and remove the special tool from the differential case. Install a new differential pinion shaft and bolt in the differential case.
    Fig 14: Installing Differential Pinion Shaft And Bolt In Differential Case

    Courtesy of FORD MOTOR CO.
14. If removed, install new differential carrier bearings.
    Fig 15: Installing Differential Carrier Bearings

    Courtesy of FORD MOTOR CO.
15. Using the special tools, check the torque required to rotate on differential side gear.
    1. Install the special tools as shown.
    2. If the original clutch plates are used, the initial breakaway torque must be within specification. The rotating torque required to turn the differential side gear with new clutch plates, may vary.
       Fig 16: Installing Special Tools

       Courtesy of FORD MOTOR CO.
16. Install the differential ring gear.
    1. Place the differential ring gear on the differential case.
    2. Hand start three bolts to align the ring gear to the differential case.
    3. Place the differential case and ring gear on the press bed with the ring gear teeth facing down.
    4. Press the ring gear into place on the differential case.
       Fig 17: Pressing Ring Gear Into Place On Differential Case

       Courtesy of FORD MOTOR CO.
17. Install the ring gear bolts and tighten to specification.
    Fig 18: Installing Ring Gear Bolts

    Courtesy of FORD MOTOR CO.

    Assembly, Differential Case and Ring Gear-Conventional 

NOTE: Coat the differential side gears and differential side gear thrust washers with rear axle lubricant.
Fig 19: Positioning Differential Thrust Washers On Differential Side Gears
Courtesy of FORD MOTOR CO.
18. Position the differential thrust washers on the differential side gears.
19. Position the differential side gears and thrust washers in the differential case.
    Fig 20: Positioning Differential Side Gears And Thrust Washers In Differential Case

    Courtesy of FORD MOTOR CO.
NOTE: Coat the differential pinion thrust washers and differential pinion gears with rear axle lubricant.
Fig 21: Assembling Differential Pinion Thrust Washers And Differential Pinion Gears
Courtesy of FORD MOTOR CO.
20. Assemble the differential pinion thrust washers and the differential pinion gears.
21. Engage the differential pinion gears opposite the differential side gears.
    Fig 22: Engaging Differential Pinion Gears Opposite Differential Side Gears

    Courtesy of FORD MOTOR CO.
22. Rotate the differential pinion gears to align with the differential pinion shaft bore.
    Fig 23: Rotating Differential Pinion Gears

    Courtesy of FORD MOTOR CO.
23. Insert the differential pinion shaft.
    Fig 24: Inserting Differential Pinion Shaft

    Courtesy of FORD MOTOR CO.
NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with sealer prior to installation.
Fig 25: Installing Differential Shaft Lock Bolt
Courtesy of FORD MOTOR CO.
24. Install a new differential shaft lock bolt and torque to specification.
25. Using the special tool, install the differential bearings.
    Fig 26: Installing Differential Bearings Using Special Tool

    Courtesy of FORD MOTOR CO.
26. Install the differential ring gear.
    1. Place the differential ring gear on the differential case.
    2. Hand start three bolts to align the holes in the differential ring gear and the differential case.
    3. Place the differential case and the differential ring gear on the press bed with the ring gear facing down.
    4. Press the ring gear into place.
       Fig 27: Pressing Ring Gear Into Place

       Courtesy of FORD MOTOR CO.
NOTE: Apply sealer to the threads of the ring gear bolts.
Fig 28: Installing Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.
27. Install the differential ring gear bolts and tighten.

    Final assembly-All Differentials 

28. Position the inner and outer bearing cups in their respective bores.
    1. After positioning the bearing cups in the bores, place the special tool on the inner bearing cup.
    2. Place the special tool on the outer bearing cup.
    3. Install the special tools.
       Fig 29: Placing Special Tool On Outer Bearing Cup

       Courtesy of FORD MOTOR CO.
29. Tighten the special tool to seat the bearing cups in the bores.
    Fig 30: Tightening Special Tool To Seat Bearing Cups In Bores

    Courtesy of FORD MOTOR CO.
NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.
Fig 31: Inserting Feeler Gauge Between Cup And Bottom
Courtesy of FORD MOTOR CO.
30. Make sure the differential pinion bearing cups are correctly seated.
NOTE: Apply a light film of lubricant on the front and rear pinion bearings.
Fig 32: Installing Pinion Bearings And Special Tools
Courtesy of FORD MOTOR CO.
31. Install the pinion bearings and special tools as shown.
NOTE: This step duplicates pinion bearing preload.
Fig 33: Threading Special Tool Onto Screw
Courtesy of FORD MOTOR CO.
32. Thread the special tool onto the screw and tighten to the specification shown.
NOTE: The special tool must be offset to obtain an accurate reading.
Fig 34: Positioning Special Tool
Courtesy of FORD MOTOR CO.
33. Position the special tool.
34. Install the special tool.
    Fig 35: Installing Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: Drive pinion bearing adjustment shims must be flat and clean.
NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in the final assembly of integral rear axle assemblies.
35. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • After the correct shim thickness has been determined, remove the special tools.
      Fig 36: Using Drive Pinion Bearing Adjustment Shim As Gauge For Shim Selection

      Courtesy of FORD MOTOR CO.
36. Using the special tools, press the inner pinion bearing and pinion shim until they are firmly seated on the pinion.
    Fig 37: Pressing Inner Pinion Bearing And Pinion Shim Using Special Tool

    Courtesy of FORD MOTOR CO.
37. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 38: Placing Drive Pinion Collapsible Spacer On Pinion Shaft

    Courtesy of FORD MOTOR CO.
38. Install a new outer pinion bearing, and rear axle drive pinion shaft oil slinger.
    Fig 39: Installing Outer Pinion Bearing, And Rear Axle Drive Pinion Shaft Oil Slinger

    Courtesy of FORD MOTOR CO.
CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one.
CAUTION: Coat the lips of the rear axle drive pinion seal with grease.
Fig 40: Placing Drive Pinion Oil Seal On Special Tool
Courtesy of FORD MOTOR CO.
39. Place the drive pinion oil seal on the special tool and drive the seal into place.
NOTE: Lubricate the pinion flange splines with rear axle lubricant.
Fig 41: Installing Drive Pinion In Drive Pinion Carrier Bore From Inside Rear Axle Housing
Courtesy of FORD MOTOR CO.
40. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer.
NOTE: Disregard the scribe marks if a new pinion flange is being installed.
Fig 42: Aligning Pinion Flange With Drive Pinion Shaft
Courtesy of FORD MOTOR CO.
41. Align the pinion flange with the drive pinion shaft.
42. With the drive pinion in the axle housing, install the pinion flange using the special tool.
    Fig 43: Installing Pinion Flange Using Special Tool

    Courtesy of FORD MOTOR CO.
43. Position the new pinion nut.
    Fig 44: Positioning Pinion Nut

    Courtesy of FORD MOTOR CO.
CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new drive pinion collapsible spacer and pinion nut must be installed.
CAUTION: The pinion flange holding tool must be removed before preload readings can be taken.
44. Using the special tool, tighten the pinion nut.
    • Rotate the pinion occasionally to make sure the drive pinion bearings are seating correctly.
    • Install a Nm (inch-pound) torque wrench on the pinion nut.
    • Rotating the pinion through several revolutions, take frequent drive pinion bearing torque preload readings until the original recorded preload reading is obtained.
    • If the original recorded preload is below specification, tighten to the appropriate specification for used bearings. If the preload is above specification, tighten the nut to the original readings as recorded.
      Fig 45: Tightening Nut

      Courtesy of FORD MOTOR CO.
45. With the pinion depth set and the pinion installed, place the differential case in the rear axle housing.
46. Install a shim as shown on the left side.
    Fig 46: Installing Shim On Left Side

    Courtesy of FORD MOTOR CO.
NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated.
Fig 47: Installing Left Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
47. Install the left bearing cap and loosely install the bearing cap bolts.
48. Install progressively larger shims on the right side until the largest shim selected can be installed by hand.
    Fig 48: Installing Progressively Larger Shims On Right Side

    Courtesy of FORD MOTOR CO.
49. Install the right side bearing cap and tighten the bolts.
    Fig 49: Installing Right Side Bearing Cap

    Courtesy of FORD MOTOR CO.
50. Rotate the differential case to make sure it rotates freely.
    Fig 50: Rotating Differential Case

    Courtesy of FORD MOTOR CO.

    Measuring Backlash 

51. Using the special tools, measure and note the differential ring gear backlash.
    • If backlash is within the specification, refer to Backlash within specification in this procedure.
    • If a zero backlash condition occurs, refer to  52.
    • If backlash is not within the specification, refer to Backlash not within specification in this procedure.
    Fig 51: Identifying Backlash Specifications

    Courtesy of FORD MOTOR CO.
    Fig 52: Measuring Differential Ring Gear Backlash Using Dial Indicator

    Courtesy of FORD MOTOR CO.

    Zero Backlash 

52. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Measure the backlash. Refer to Measuring backlash in this procedure.
    Fig 53: Identifying Differential Bearing Shims (1 Of 2)

    Courtesy of FORD MOTOR CO.

    Backlash Not Within Specification 

53. To increase or decrease backlash, remove the differential bearing caps and install a thicker shim and a thinner shim accordingly.
    • If backlash is not within the specification, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount.
      Fig 54: Identifying Differential Bearing Shims (2 Of 2)

      Courtesy of FORD MOTOR CO.
54. Rotate the differential assembly several times to verify that the differential bearings seated correctly.
    Fig 55: Identifying Differential Bearings Seating Position

    Courtesy of FORD MOTOR CO.
55. Using the special tools, recheck the backlash.
    • If backlash is within the specification, refer to Backlash within specification in this procedure. If backlash is not within the specification, repeat Backlash not within specification in this procedure.
      Fig 56: Checking Backlash In Dial Indicator

      Courtesy of FORD MOTOR CO.

    Backlash Within Specification 

56. Remove the bolts and the differential bearing caps.
57. To establish differential bearing preload, increase both left and right differential bearing shim sizes by the specification shown.
    Fig 57: Removing Bolts And Differential Bearing Caps Using Special Tool

    Courtesy of FORD MOTOR CO.
58. Install the differential bearing caps and bolts.
    Fig 58: Installing Differential Bearing Caps And Bolts

    Courtesy of FORD MOTOR CO.
59. Using the special tools, recheck the backlash.
    Fig 59: Checking Backlash Using Special Tool

    Courtesy of FORD MOTOR CO.
60. Remove the axle assembly from the holding fixture and install the torque arm.
    Fig 60: Removing Axle Assembly From Holding Fixture

    Courtesy of FORD MOTOR CO.
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 1 hour before filling with lubricant to make sure the silicone sealant has cured correctly.
Fig 61: Installing Differential Housing Cover
Courtesy of FORD MOTOR CO.
61. Install the differential housing cover and tighten the differential housing cover bolts.