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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 44 & 50 Axles

Dana 44 & 50 Axles

  1. With drive pinion depth and preload adjustments properly made, install differential case into housing. Differential master bearings should still be on case. Ensure differential case is fully seated in carrier bores. Set dial indicator so that tip is against head of ring gear mounting bolt at 90 degrees to bolt.
  2. 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. Note dial indicator reading. Repeat this procedure until same reading is obtained each time.
  3. This reading is thickness of shim pack that must go under differential side bearing on ring gear side of case. Remove master bearings. Place shim pack of correct thickness on ring gear hub.
  4. Drive side bearing onto case using Side Bearing Installer (T80T-4000-J). Subtract thickness of shim pack installed on ring gear side of case from total differential case end play. Total differential case end play was recorded in step 4) under DIFFERENTIAL CASE  .
  5. Add .010" (.25 mm) preload to remaining end play figure obtained in previous step. Total is thickness of shim pack that is to be installed on hub of differential case opposite ring gear (drive pinion side of case).
  6. Place shim pack on case hub and drive side bearing onto case using side bearing installer. Support case with Step Plate (D80L-630-5) to protect side bearing already installed on ring gear side of case. Install housing spreader and dial indicator on carrier housing. Spread housing maximum of .010" (.25 mm). Remove dial indicator.
  7. Place side bearing races on side bearings. Install case into carrier housing. Use soft-faced hammer to seat case assembly in carrier bore. If partial or non-hunting/partial ring and pinion gear set is being used, line up mating marks on gears. Remove housing spreader and dial indicator.
  8. Install side bearing caps. Ensure letters stamped on caps match letters stamped on housing. Tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS  table. Check ring and pinion gear backlash in 3 places equally spaced around ring gear. Backlash range is .005-.009" (.13-.23 mm) with maximum variation between 3 measurements of .003" (.08 mm).
  9. To change backlash readings, move shims from one side of differential case to other. Total thickness of end play shim packs must not change. When backlash adjustment is completed, check tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in the DRIVE AXLES Section.
  10. 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. Using 2 guide pins, install carrier on left axle arm assembly.
  11. Use new carrier bolts with adhesive-treated threads or clean old bolts and apply locking compound. Tighten carrier bolts. Install and tighten support arm tab bolts on side of carrier. Allow one hour curing time for sealant. Fill assembly with hypoid lubricant.
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