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Home >> Ford >> 1992 >> Explorer 4D Utility, RWD, Automatic >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Drive Axle - Front (DANA Ifs) >> Overhaul >> Ring & Pinion Gear Backlash >> Dana 35 Axle

Dana 35 Axle

  1. With drive pinion depth and preload adjustments properly made, install differential case into housing. Differential master bearings should still be on case. Force differential case away from drive pinion gear so that case is fully seated into cross bores of carrier.
  2. Set dial indicator so that tip is against head of ring gear bolt at 90 degrees to bolt. Rock ring gear so that teeth of ring gear mesh fully with drive pinion gear teeth. Force ring gear teeth against drive pinion gear teeth and zero dial indicator. Force ring gear and case away from drive pinion gear. Repeat this procedure until same reading is obtained each time.
  3. This reading, less .008" (.20 mm) for backlash, is thickness of shim pack that must go under differential side bearing on ring gear side of case. Remove case from carrier. Remove master bearings from case. Place correct shim pack on ring gear hub of case. Place side bearing on hub of case. Drive bearing onto case using Step plate (D80L-630-4), Side Bearing Replacer (T85M-4221-A) and Handle (T80T-4000-W).
  4. To determine the correct amount of shims to place on pinion gear side hub, subtract thickness of shim pack installed on ring gear side of case from total of differential case end play. Total differential case end play was recorded in step 4) under DIFFERENTIAL CASE  . Add a preload of .002" (.05 mm) to figure calculated for shim pack thickness on side opposite ring gear.
  5. Place required thickness shim pack on hub of case opposite ring gear. Place step plate on ring gear side bearing to protect bearing. Drive remaining side bearing onto case with side bearing replacer. Install side bearing races on side bearings.
  6. Install housing spreader and dial indicator on carrier. Spread case to maximum of .010" (.25 mm). Install differential case into carrier. Use soft-faced hammer to ensure that case seats fully into carrier bore. Use care to avoid damaging teeth of ring and pinion gears.
  7. If partial or non-hunting/partial ring and pinion gear set is being used, line up mating marks on gears. Remove spreader and dial indicator. Install side bearing caps, making sure that letters stamped on caps match letters stamped on housing.
  8. Tighten the bearing cap bolts to proper specification. See TORQUE SPECIFICATIONS  table. Check ring and pinion gear backlash in 3 places equally spaced around ring gear. Backlash range is .005-.008" (.13-.20 mm) with maximum variation between 3 measurements of .003" (.08 mm).
  9. If backlash figure is too high, ring gear must be moved closer to drive pinion gear. If backlash figure is too low, ring gear must be moved away from drive pinion gear. To change backlash readings, move shims from one side of differential case to other. Total thickness of end play shim packs must not change.
  10. When backlash adjustment is completed, check tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in the GENERAL INFORMATION section. Pattern will be correct if assembly and adjustments have been done properly.
  11. When backlash is correct, apply bead of sealant to mating surfaces of carrier mounting face support arm. Bead should be 1/8" to 1/4" high and 1/4" to 1/2" wide. Install carrier on left axle arm assembly, using 2 carrier bolts as guide pins and being careful not to smear sealant.
  12. Install remaining carrier bolts and tighten to specification in clockwise pattern. Install and tighten carrier shear bolt and nut. Allow one hour curing time for sealant. Fill assembly with hypoid lubricant.
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