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Home >> Ford >> 1996 >> Aerostar Van Window >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Drive Axle - Front (DANA 28-2) >> Overhaul >> Differential Assembly >> Ring & Pinion Gear Backlash

Ring & Pinion Gear Backlash

  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 case is fully seated in cross bores of housing.
  2. Set dial indicator so tip is against head of ring gear bolt at 90 degrees to bolt. Rock ring gear so 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. Read gauge. Repeat this procedure until same reading is obtained each time.
  3. This reading, less .005" (.13 mm), is thickness of shim pack that must go under differential side bearing on ring gear side of case. Remove case from axle housing. 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-630-3), Side Bearing Replacer (T83T-4221-A) and Handle (T80T-4000-W).
  4. To determine 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 previously determined in steps 1)  -4)  of DIFFERENTIAL CASE REASSEMBLY procedure. Add .010" (.25 mm) to figure determined 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 housing to maximum of .015" (.37 mm). Install differential case in housing. Use soft-faced hammer to ensure that case seats fully in housing bore. Use care to avoid damaging teeth of ring and pinion gears.
  7. Remove housing spreader and dial indicator. Install side bearing caps, ensuring letters stamped on caps match letters stamped on housing. Tighten bearing cap bolts to proper specification. See TORQUE SPECIFICATIONS  .
  8. Check ring and pinion gear backlash in 3 places equally spaced around ring gear. Backlash range is .005-.008" (.13-20 mm) with allowable maximum variation of .003" (.08 mm). If backlash figure is too high, move ring gear closer to drive pinion gear.
  9. If backlash figure is too low, move ring gear away from drive pinion gear. To change backlash readings, move shims from one side of differential case to other. DO NOT change total thickness of end play shim packs.
  10. When backlash adjustment is completed, check tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Pattern will be correct if assembly and adjustments have been done properly. When backlash is correct, apply continuous bead of RTV sealant, 1/4 - 3/8" wide, on housing.
  11. Sealant bead should not pass over or outside holes. Install housing cover. To complete installation, reverse removal procedure. Allow one hour cure time before filling differential.
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