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Differential Ring Gear and Pinion: Installation

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  1. Using the special tools, install the new differential bearings. Use Special Service Tool: 205-010 (T57L-4221-A2) Installer, Differential Side Bearing.
    GFD271893Courtesy of FORD MOTOR COMPANY
  2. Install the ring gear onto the differential carrier. Align the ring gear using 3 new bolts. Using the general equipment: press the ring gear into place. Use the General Equipment: Hydraulic Press
    GFD271894Courtesy of FORD MOTOR COMPANY
  3. Install the remaining new ring gear bolts.

    Torque: 94 lb.ft (128 Nm)

    GFD271895Courtesy of FORD MOTOR COMPANY
  4. If removed.Using the special tool, install the new drive pinion oil baffle. Use Special Service Tool: 205-D044 (D81T-4221-A) Installer, Differential Carrier Bearing.
    GFD271896Courtesy of FORD MOTOR COMPANY
  5. NOTE: Make sure the drive pinion bearing cups are seated correctly or damage to the components may occur.

    Using the special tools, install the new drive pinion inner and outer bearing cups. Use Special Service Tool: 205-024 (T67P-4616-A) Installer, Drive Pinion Bearing Cup.

    GFD271897Courtesy of FORD MOTOR COMPANY
  6. NOTE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly or damage to the component may occur.
    NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

    Assemble the special tools using the new inner and outer drive pinion bearings. Use Special Service Tool: 205-105 (T76P-4020-A3) Adapter for 205-S127., 205-109 (T76P-4020-A9) Adapter for 205-S127., 205-110 (T76P-4020-A10) Gauge Block., 205-111 (T76P-4020-A11) Handle., 205-129 (T79P-4020-A18) Disc, Guage.

    Torque: 19 lb.in (2.2 Nm)

    GFD271898Courtesy of FORD MOTOR COMPANY
  7. Rotate the special tools several half turns to ensure correct seating of the drive pinion bearings. Use Special Service Tool: 205-110 (T76P-4020-A10) Gauge Block.
    GFD271899Courtesy of FORD MOTOR COMPANY
  8. Install the special tool, the differential bearing caps and the differential bearing cap bolts. Use Special Service Tool: 205-336 (T93P-4020-A) Gauge Tube, Drive Pinion.

    Torque: 77 lb.ft (105 Nm)

    GFD271900Courtesy of FORD MOTOR COMPANY
  9. NOTE: Drive pinion bearing adjustment shims must be flat and clean.
    NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.

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

    • After the correct drive pinion bearing adjustment shim thickness has been determined, remove all of the Adapters. Use Special Service Tool: 205-111 (T76P-4020-A11) Handle., 205-109 (T76P-4020-A9) Adapter for 205-S127., 205-110 (T76P-4020-A10) Gauge Block., 205-129 (T79P-4020-A18) Disc, Guage., 205-336 (T93P-4020-A) Gauge Tube, Drive Pinion.

    GFD271901Courtesy of FORD MOTOR COMPANY
  10. Notice the (+) or (-) etching on the pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures.

    • For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 in) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.

    GFD271902Courtesy of FORD MOTOR COMPANY
  11. NOTE: The same drive pinion bearing from the previous steps must be used.

    Install the drive pinion bearing and the selected drive pinion bearing adjustment shim until they are firmly seated on the drive pinion. Use Special Service Tool: 205-005 (T53T-4621-C) Installer, Drive Pinion Bearing Cone. Use the General Equipment: Hydraulic Press

    GFD271903Courtesy of FORD MOTOR COMPANY
  12. Install the pinion gear.
    GFD271904Courtesy of FORD MOTOR COMPANY
  13. Install the new drive pinion collapsible spacer.
    GFD271905Courtesy of FORD MOTOR COMPANY
  14. Install the outer drive pinion bearing.
    GFD271906Courtesy of FORD MOTOR COMPANY
  15. Install the outer drive pinion oil slinger.
    GFD271883Courtesy of FORD MOTOR COMPANY
  16. Install the drive pinion flange and seal. Refer to: Drive Pinion Flange and Seal .
  17. NOTE: It is necessary to loosely install the bearing caps and bolts to hold the differential in place.

    Install the differential carrier and the differential carrier bearing cups as a assembly.

    GFD271907Courtesy of FORD MOTOR COMPANY
  18. Install a 6.12 mm (0.241 in) differential bearing shim on the LH side of the differential bearing.
    GFD271908Courtesy of FORD MOTOR COMPANY
  19. NOTE: Apply pressure toward the left side to make sure the left differential bearing cap is seated.

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

    GFD271909Courtesy of FORD MOTOR COMPANY
  20. NOTE: Apply pressure toward the left side to make sure the left differential bearing cap is seated.

    Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.

    GFD271910Courtesy of FORD MOTOR COMPANY
    1. Install the RH differential bearing cap and bolts.
    2. Tighten the differential bearing cap bolts.

      Torque: 77 lb.ft (105 Nm)

    GFD271911Courtesy of FORD MOTOR COMPANY
  22. Rotate the differential carrier to make sure it turns freely.
    GFD271912Courtesy of FORD MOTOR COMPANY
  23. Using the dial indicator, measure the differential ring gear backlash at 4 equally spaced points.

    • To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

    GFD271869Courtesy of FORD MOTOR COMPANY
  24. NOTE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the differential bearing caps in their original positions or damage to the component may occur.

    Remove the differential cap bolts, differential caps and the carrier assembly.

    GFD271913Courtesy of FORD MOTOR COMPANY
    1. Measure the thickness of the selected right and left bearing shims. Use the General Equipment: Caliper Gauge
    2. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 in).
    GFD271914Courtesy of FORD MOTOR COMPANY
  26. Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier Spreader. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 308-021 (T75L-4201-A) Gauge, Clutch Housing., 205-001 (TOOL-4000-E) Spreader, Differential Carrier.
    GFD271915Courtesy of FORD MOTOR COMPANY
  27. NOTE: Overspreading may damage the component. Do not spread the differential housing more then 0.762 mm (0.030 in).
    NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final Dial Indicator reading.

    Spread the differential housing to the specification.

    1. Adjust the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge to zero. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 308-021 (T75L-4201-A) Gauge, Clutch Housing.
    2. Tighten the screw until spreading the differential housing to the specification.
    3. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.

    GFD271916Courtesy of FORD MOTOR COMPANY
  28. NOTE: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, the aluminum housing may be damaged.

    Place the differential bearing shims in the differential housing.

    GFD271917Courtesy of FORD MOTOR COMPANY
  29. Install the differential carrier.

    • Position the differential bearing cups on the differential bearings.

    • Lower the differential carrier in place between the differential bearing shims.

    GFD271918Courtesy of FORD MOTOR COMPANY
  30. NOTE: The fixture mounting bolts must have the minimum of 12.7 mm (0.500 In) of thread engagement in the carrier or damage to the component may occur.
    NOTE: Always install the differential bearing caps in their original positions or damage to the component may occur.
    NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.

    • With the differential housing spread to 0.762 mm (0.030 in) maximum. Install the differential caps and bolts in their original locations and positions. Use Special Service Tool: 205-001 (TOOL-4000-E) Spreader, Differential Carrier., 205-368 (T96T-4000-A) Adapter for Differential Housing Spreader., 205-335 (T93P-4000-A) Spreader, Differential Housing (Plate).

    • NOTE: Finger tighten the differential bearing cap bolts prior to releasing the carrier spreader.

      Install the differential bearing caps and the differential bearing cap bolts in their original locations and positions.

    GFD271919Courtesy of FORD MOTOR COMPANY
    1. Loosen and Remove the special tools. Use Special Service Tool: 205-001 (TOOL-4000-E) Spreader, Differential Carrier., 205-368 (T96T-4000-A) Adapter for Differential Housing Spreader., 205-335 (T93P-4000-A) Spreader, Differential Housing (Plate).
    2. Tighten the differential bearing cap bolts.

      Torque: 77 lb.ft (105 Nm)

    GFD271868Courtesy of FORD MOTOR COMPANY
  32. Rotate the differential carrier to make sure it turns freely.
    GFD271912Courtesy of FORD MOTOR COMPANY
  33. Install the Dial Indicator Gauge with Holding Fixture at the 12 o'clock position and recheck the ring gear backlash. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD271869Courtesy of FORD MOTOR COMPANY
  34. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  35. Verify an acceptable pattern check. Refer to: Front Drive Axle .
  36. NOTE: Make sure that the mating surface and the bore is free of corrosion and foreign material, avoid particles getting into the bore. Particles might stick on the vent valve assembly and cause damage to vent valve.

    Clean the mating surface of the axle and the axle tube.

    GFD271870Courtesy of FORD MOTOR COMPANY
  37. Apply a new continuous bead of sealant to the differential housing as shown in the figure.

    Material

    : Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    GFD271871Courtesy of FORD MOTOR COMPANY
  38. Install the axle tube and the axle tube bolts.

    Torque: 54 lb.ft (73 Nm)

    GFD271858Courtesy of FORD MOTOR COMPANY
  39. Install the new inner and outer circlips.
    GFD271872Courtesy of FORD MOTOR COMPANY
  40. NOTE: The axle shaft is not fully seated until the circlip is engaged with the differential side gear.

    Install the axle shaft.

    GFD271848Courtesy of FORD MOTOR COMPANY
  41. NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying the new silicone gasket.

    Clean the gasket mating surface of the axle and the differential housing cover.

    GFD271873Courtesy of FORD MOTOR COMPANY
  42. 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 new continuous bead of sealant to the differential housing cover as shown in the figure.

    Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    GFD271874Courtesy of FORD MOTOR COMPANY
  43. Install the differential cover and differential cover bolts.

    Torque: 24 lb.ft (32 Nm)

    GFD271857Courtesy of FORD MOTOR COMPANY
  44. Install the front axle assembly. Refer to: Axle Assembly .
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