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Differential Assembly: Reassembly

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CAUTION: A new oil baffle must be installed located between inner drive pinion bearing cup and axle housing bore.
  1. Apply a light coat of rear axle lubricant to the drive pinion bearing cup bore. Using the Drive Pinion Bearing Cup Installer (205-054, T71P-4616-A), install a new oil baffle, inner and outer drive pinion bearing cups. See Fig 1 .
    2. NOTE: The Gauge Block (205-110, T76P-4020-A10) must be offset to obtain an accurate reading. Rotate the Gauge Block (205-110, T76P-4020-A10) several half turns to correctly seat the drive pinion bearings.
  2. Install drive pinion bearing preload adapters and preload the inner and outer drive pinion bearings. See Fig 2 . Position the gauge block at a 45 degree angle as shown. See Fig 3 .
    3. CAUTION: If the drive pinion is marked with a plus (+) reading, this amount must be subtracted from the thickness measured. If the drive pinion is marked with a minus (-) reading, this amount must be added to the thickness measured.
  3. Install the Gauge Tube (205-108, T76P-4020-A7) and install the bearing caps and bolts. See Fig 4 . Measure and record the clearance between the gauge tube and the gauge block. Select and check the correct drive pinion position shim as necessary.
    4. CAUTION: The same drive pinion bearings and drive pinion bearing cups used in the drive pinion position shim selection procedure must be used in the final axle assembly.
  4. Position the drive pinion position shim and drive pinion bearing. Using the Bearing/Oil Seal Plate (205-090, T75L-1165-B) and Drive Pinion Bearing Cone (205-011, T57L-4621-B), firmly seat the drive pinion position shim and pinion bearing onto the drive pinion. See Fig 5 .
    5. CAUTION: Do not reuse the old collapsible spacer.
  5. Install a new collapsible spacer onto drive pinion. Using the drive pinion socket and drive pinion nut holding tool, install the drive pinion and a new drive pinion nut. Rotate the drive pinion counterclockwise until all end play is removed then tighten the drive pinion nut to specification. See TORQUE SPECIFICATIONS  .
    6. CAUTION: If the rotational torque is less than specification, tighten the drive pinion nut in small increments until it is within specification. Do not tighten the drive pinion nut more than 500 ft. lbs. (678 N.m) or the collapsible spacer will be damaged. If the rotation torque is higher than specification, the collapsible spacer has been compressed too far and a new collapsible spacer must be installed.
    NOTE: When tightening the drive pinion nut to remove initial end play, torque may exceed the maximum specification. Once end play is removed and the collapsible spacer has started to collapse, the torque should drop into the specified range. Rotate the drive pinion 10 revolutions before taking the reading.
  6. Check the drive pinion rotational torque and adjust as necessary. See TORQUE SPECIFICATIONS  . The differential carrier should move freely in the axle housing. Using the Differential Bearing Gauges (205-207A), install the differential case into the axle housing. See Fig 6 .
  7. Seat the differential carrier away from the drive pinion then push the differential carrier toward the drive pinion while measuring and recording the differential case total end play. See Fig 7 . Repeat this step until a same reading is obtained twice.
  8. Remove the differential carrier and the differential bearing gauges. Note which side each differential bearing gauge was removed from so they can be installed on the same side of differential carrier for the next measurement with the ring gear installed.
    9. CAUTION: If reusing original pinion gears, side gears or thrust washers, install in the same locations that they were removed.
  9. Position the side gears and side gear thrust washers. Install the 2 pinion gears, 2 side gears and 4 thrust washers. See Figure . Rotate the pinion gears and pinion gear thrust washers to the differential pinion shaft hole in the differential case. Apply rear axle lubricant to the pinion gears, side gears and thrust washers.
    10. CAUTION: Gear teeth have sharp edges. Use care when handling the drive pinion. Failure to follow these instructions may result in personal injury.
  10. Install the differential pinion shaft and differential pinion shaft lock pin. See Figure . Position and install the ring gear onto the differential carrier. Install NEW ring gear bolts in an alternately and evenly pattern. Tighten ring gear bolts to specification. See TORQUE SPECIFICATIONS  .
  11. Install the differential carrier into the axle housing. Install the differential bearing gauges on the same ends of the differential carrier as they were previously installed. See Fig 6 . Locate the tip of the dial indicator on the flat surface of one of the ring gear bolts. See Fig 8 .
  12. Seat the differential carrier away from the drive pinion then push the differential carrier toward the drive pinion while measuring and recording the differential case total end play. See Fig 8 . Repeat this step until a same reading is obtained twice. Remove differential bearing gauges.
    13. NOTE: If the special tools do not measure 18.136 mm (0.714 in) +/- 0.025 mm (0.001 in), the numbers in step one will be overstated by the difference measured on each differential bearing gauge. The number in step 2 will be overstated by the difference measured on differential bearing gauge. Adjustments to the shim pack will have to be made in order to prevent bearing preloads from becoming excessive.
  13. Calculate thickness for the differential carrier bearing shims. Measure the width of the differential bearing gauges used on the ends of the differential carrier and select the appropriate shims as necessary.

    1. Step 1

      Measure differential carrier end play without ring gear installed and record measurement. See Fig 7 .

    2. Step 2

      Measure differential carrier end play with ring gear installed and record measurement. See Fig 8 .

    3. Step 3

      Subtract measurement recorded in step 2 from measurement recorded in step one.

    4. Step 4

      Total shims necessary for the ring gear side of differential carrier, equals the measurement recorded in step 2 plus 0.003" (0.076 mm). See EXAMPLE OF SELECTING DIFFERENTIAL CARRIER BEARING SHIMS  table.

    5. Step 5

      Total shims necessary for the opposite side of the differential carrier, equals the measurement recorded in step 3 plus 0.010" (0.25 mm). See EXAMPLE OF SELECTING DIFFERENTIAL CARRIER BEARING SHIMS  table.
    14. CAUTION: Overspreading can damage the axle housing.
  14. Using the adapter handle and Differential Bearing Installer (205-206, T83T-4221-A), install the differential case bearings and correct shims. See Fig 9 . Using the differential spreader and adapter plates, spread the axle housing and install the differential carrier. See Figure .
  15. Remove the differential spreader and adapter plates. Install the differential carrier bearing caps. Position the differential carrier bearing caps in the position they were removed. Install the differential carrier bearing cap bolts. Tighten differential carrier bearing cap bolts to specification. See TORQUE SPECIFICATIONS  .
    16. NOTE: The ring gear backlash should be measured at 3 equally spaced points on the ring gear. If the reading is high, the ring gear must be moved closer to the drive pinion by adding shims to the ring gear side from the opposite side. If the readings are low, the ring gear must be moved away from the drive pinion by removing shims from the ring gear side and adding to the opposite side.
  16. Measure and adjust the ring gear backlash as necessary. See Fig 10 . Position the axle assembly with the drive pinion stem facing upward.
  17. Measure and record the total turning torque to rotate the drive pinion and adjust as necessary. The total turning torque should be the drive pinion rotational torque plus 6-10 INCH lbs. (0.68-1.13 N.m). See TORQUE SPECIFICATIONS  .
  18. If the total turning torque is too high, subtract an equal amount of shims from each side of the differential carrier bearings. If the total turning torque is too low, add an equal amount of shims to both sides of the differential carrier bearings.
    19. NOTE: Lubricate the needle bearings with premium long life grease prior to installation of axle shaft bearings.
  19. Using the adapter handle and axle bearing installer, install the axle shaft bearings. See Figure . Using the adapter handle and axle oil seal installer, install the axle shaft seals. See Figure .
EXAMPLE OF SELECTING DIFFERENTIAL CARRIER BEARING SHIMS

Steps Procedure Example
1 Total Differential Case End Play Without Ring Gear Installed 0.042" (1.066 mm)
2 Total Differential Case End Play With Ring Gear Installed. 0.026" (0.660 mm)
3 Step One Minus Step 2 0.016" (0.406 mm)
4 Total Shims Necessary For The Ring Gear Side Of Differential Carrier. Add 0.003" (0.076 mm) To Measurement In Step 2 0.029" (0.736 mm)
5 Total Shims Necessary For The Opposite Side Of Differential Carrier. Add 0.01" (0.25 mm) To Measurement In Step 3 0.026" (0.660 mm)
Fig 1: Installing Oil Baffle & Drive Pinion Inner & Outer Bearing Cups
G00186928Courtesy of FORD MOTOR CO.
Fig 2: Identifying Drive Pinion Bearing Preload Adapters & Setting Bearing Preload
G00186929Courtesy of FORD MOTOR CO.
Fig 3: Positioning Drive Pinion Bearings
G00034134Courtesy of FORD MOTOR CO.
Fig 4: Installing Gauge Tube
G00186930Courtesy of FORD MOTOR CO.
Fig 5: Installing Drive Pinion Bearing
G00186931Courtesy of FORD MOTOR CO.
Fig 6: Identifying Differential Bearing Gauges
G00186932Courtesy of FORD MOTOR CO.
Fig 7: Measuring Differential Case End Play (Without Ring Gear)
G00186933Courtesy of FORD MOTOR CO.
Fig 8: Measuring Differential Case End Play (With Ring Gear)
G00186934Courtesy of FORD MOTOR CO.
Fig 9: Installing Differential Side Carrier Bearing & Shims
G00186935Courtesy of FORD MOTOR CO.
Fig 10: Measuring Differential Backlash
G00186936Courtesy of FORD MOTOR CO.
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