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Differential Bearings: Installation

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Always install new gaskets and seals when assembling the axle. When building the subassembly, lubricate each component with clean rear axle lubricant. Also, lubricate the subassembly when installing it into the differential housing. Tighten all fasteners to specification.
  1. Lubricate the new differential drive pinion bearing cups.
  2. Using the special tools, install the differential drive pinion bearing cups.
    Fig 1: Installing Differential Drive Pinion Bearing Cups
    G03434799Courtesy of FORD MOTOR CO.
    3. NOTE: Apply a light film of oil to the differential pinion bearings before installing them.
    Fig 2: Assembling Assemble & Positioning Bearings & Special Tools
    G03434800Courtesy of FORD MOTOR CO.
  3. Assemble and position the following in the differential housing.
    1. Position the Screw.
    2. Position the Aligning Adapter.
    3. Position the inner differential pinion bearing.
    4. Position the Gauge Disc.
    5. Position the Gauge Block.
    6. Position the outer differential pinion bearing.
    7. Thread on the Handle.
  4. Using a Nm (pound-inch) torque wrench, tighten the Handle.
    Fig 3: Tightening Special Tool Handle
    G03434801Courtesy of FORD MOTOR CO.
    5. NOTE: Offset the Gauge Block to obtain an accurate reading.
    Fig 4: Rotating Gauge Block To Ensure Differential Pinion Bearings Seat Correctly
    G03434802Courtesy of FORD MOTOR CO.
  5. Rotate the Gauge Block several half turns to ensure the differential pinion bearings seat correctly, and position the Gauge Block as shown.
  6. Install the special tool and the paper shipping tags.
    1. Position the special tool and the paper shipping tags.
    2. Install the differential bearing caps.
    3. Install the bolts.
      • Tighten to 61 Nm (45 lb-ft).
    Fig 5: Installing Special Tool & Paper Shipping Tags
    G03434803Courtesy of FORD MOTOR CO.
    7. NOTE: Use a feeler gauge, or flat, clean drive pinion position shims as a measuring device.
    NOTE: Selection of a shim that is too thick results in deep tooth contact at final assembly. Do not attempt to force the gauge or shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.
    Fig 6: Measuring Between Gauge Block & Gauge Tube
    G03434804Courtesy of FORD MOTOR CO.
  7. Using a feeler gauge, or a flat, clean drive pinion position shim, measure between the Gauge Block and the Gauge Tube. Record the measurement.
    • Remove the special tools after determining the correct shim thickness.
  8. Select the correct thickness drive pinion position shim.
    • New drive pinion position shims are available in 0.762 mm (0.030 in), 0.8128 mm (0.032 in), 0.8636 mm (0.034 in), 0.9144 mm (0.036 in), 0.9652 mm (0.038 in), 1.016 mm (0.040 in), 1.0668 mm (0.042 in), 1.1176 mm (0.044 in), 1.1684 mm (0.046 in), 1.2192 mm (0.048 in),1.27 mm (0.050 in) and 1.3208 mm (0.052 in) thickness.
    • Notice the plus (+), minus (-), or zero (0) etching on the drive pinion, and adjust the thickness of the new shim. If the etching is positive, subtract the number from the selected position shim. If the etching is negative, subtract the number from the selected position shim.
    • The selected shim thickness should be very close to the recorded thickness of the original position shim.
    Fig 7: Selecting Correct Thickness Drive Pinion Position Shim
    G03434805Courtesy of FORD MOTOR CO.
  9. Install the pinion position shim and the differential pinion bearing.
    • Using the special tool and a suitable press, seat the differential pinion bearing firmly against the pinion position shim.
    Fig 8: Installing Pinion Position Shim & Differential Pinion Bearing
    G03434806Courtesy of FORD MOTOR CO.
  10. Install a new collapsible spacer.
    Fig 9: Installing Collapsible Spacer
    G03434807Courtesy of FORD MOTOR CO.
  11. Install the differential pinion bearing and the front axle drive pinion shaft oil slinger.
    Fig 10: Installing Differential Pinion Bearing & Front Axle Drive Pinion Shaft Oil Slinger
    G03434808Courtesy of FORD MOTOR CO.
    12. CAUTION: Installing the pinion seal without the correct tool can result in early seal failure.
    CAUTION: If the pinion seal becomes cocked during installation, remove it and install a new one.
    NOTE: Pinion seal must be fully seated all the way around or pinion seal damage will occur.
    Fig 11: Installing Pinion Seal
    G03434809Courtesy of FORD MOTOR CO.
  12. Using the special tool, install the pinion seal.
  13. Lightly lubricate the pinion gear splines.
  14. Position the pinion gear in the axle housing.
    Fig 12: Positioning Pinion Gear In Axle Housing
    G03434810Courtesy of FORD MOTOR CO.
    15. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange.
    Fig 13: Aligning Index Marks & Installing Pinion Flange
    G03434811Courtesy of FORD MOTOR CO.
  15. Align the index marks and install the pinion flange.
  16. Install the new nut hand-tight.
    Fig 14: Installing Nut Hand-Tight
    G03434812Courtesy of FORD MOTOR CO.
    17. CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.
    NOTE: Remove the special tool before taking the differential pinion bearing preload reading.
    Fig 15: Tightening Pinion Flange Nut
    G03434813Courtesy of FORD MOTOR CO.
  17. Use the special tool to hold the pinion flange while tightening the nut to set the preload.
    • Rotate the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. The final rotational reading must be 1.7-3.4 Nm (15-30 lb-in).
  18. Install the special tool.
    Fig 16: Installing Special Tool
    G03434814Courtesy of FORD MOTOR CO.
  19. Install the differential case in the differential housing.
    Fig 17: Installing Differential Case In Differential Housing
    G03434815Courtesy of FORD MOTOR CO.
    20. NOTE: Repeat this step until obtaining a consistent reading.
    Fig 18: Measuring Total End Play
    G03434816Courtesy of FORD MOTOR CO.
  20. Measure the total end play.
    1. Install the special tool.
    2. Force the differential case as far as possible away from the indicator. Position the indicator tip on the machined surface and adjust it to measure full travel. With force still applied, set the indicator to zero.
    3. Force the differential case as far as possible in the opposite direction.
    4. Record the total end play reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A. Refer to DIFFERENTIAL BEARING SHIM SELECTION PROCEDURE WORKSHEET  table.
  21. Remove the special tool, and remove the differential case.
    1. Remove the special tool.
    2. Remove the differential case.
    Fig 19: Removing Special Tool & Differential Case
    G03434817Courtesy of FORD MOTOR CO.
    22. CAUTION: Do not reuse the original bolts.
    Fig 20: Installing Differential Ring Gear
    G03434818Courtesy of FORD MOTOR CO.
  22. Using a suitable press, install the differential ring gear.
    1. Position the differential ring gear and the differential case. Start 2 or 3 new bolts to align the holes in the ring gear and the differential case.
    2. Using a suitable press, install the differential ring gear.
  23. Install the remaining new differential ring gear bolts.
    • Tighten to 122 Nm (90 lb-ft).
    Fig 21: Installing Remaining New Differential Ring Gear Bolts
    G03434819Courtesy of FORD MOTOR CO.
  24. Install the special tool and position the assembly in the differential housing.
    1. Install the special tool.
    2. Position the assembly in the differential housing.
    Fig 22: Installing Special Tool & Positioning Assembly In Differential Housing
    G03434820Courtesy of FORD MOTOR CO.
  25. Position the special tool.
    Fig 23: Positioning Special Tool
    G03434821Courtesy of FORD MOTOR CO.
  26. Force the differential ring gear into mesh with the pinion gear (zero backlash). With force still applied, set the special tool to zero.
    Fig 24: Zeroing Dial Indicator
    G03434822Courtesy of FORD MOTOR CO.
  27. Force the differential ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line D. Refer to DIFFERENTIAL BEARING SHIM SELECTION PROCEDURE WORKSHEET  table.
    Fig 25: Forcing Differential Ring Gear Away From Pinion Gear
    G03434823Courtesy of FORD MOTOR CO.
  28. Remove the special tool.
    Fig 26: Removing Special Tool
    G03434824Courtesy of FORD MOTOR CO.
  29. Remove the differential case from the differential housing. Remove the special tool from the differential case hubs.
    Fig 27: Removing Special Tool From Differential Case Hubs
    G03434825Courtesy of FORD MOTOR CO.
  30. Complete the worksheet, and select the appropriate thickness differential shims. New differential shims are available in 0.0762 mm (0.003 in), 0.127 mm (0.005 in), 0.25 mm (0.010 in) and 0.762 mm (0.030 in) thickness.
    DIFFERENTIAL BEARING SHIM SELECTION PROCEDURE WORKSHEET

    Line Item Result (Actual) Result (Example)
    A Total End Play Reading (Without Gears) - 2.032 mm (0.080 in)
    B Add Preload +0.2032 mm (+0.008 in) +0.2032 mm (+0.008 in)
    C Total (Add A & B) - 2.2352 mm (0.088 in)
    D End Play Measurement (With Gears) - 1.0414 mm (0.041 in)
    E Subtract The Shim Thickness On The Ring Gear Side -0.0762 mm (-0.003 in) -0.0762 mm (-0.003 in)
    F Total (Subtract E From D) (Thickness Of Shims To Place On The Ring Gear Side) - 0.9652 mm (0.038 in)
    G Total (Subtract F From C) (Thickness Of Shims To Place On The Drive Pinion Side) - 1.27 mm (0.050 in)
  31. Install the differential shims and the differential bearing.
    1. Position the differential shims and the differential bearing.
    2. Using a suitable press, install the differential bearing.
      • Repeat this step for opposite side of the differential case.
    Fig 28: Installing Differential Shims & Differential Bearing
    G03434826Courtesy of FORD MOTOR CO.
  32. Install the special tools.
    • Position the Clutch Housing Alignment Adapter needle in the Housing Spreader Adapter hole.
    Fig 29: Installing Special Tools
    G03434827Courtesy of FORD MOTOR CO.
    33. CAUTION: Over spreading can damage the differential housing.
    Fig 30: Spreading Differential Housing To Specification
    G03434828Courtesy of FORD MOTOR CO.
  33. Spread the differential housing to the specification.
  34. Remove the special tools.
    Fig 31: Removing Special Tools
    G03434829Courtesy of FORD MOTOR CO.
    35. NOTE: Push the differential case downward to fully seat the differential bearing cups in the differential housing.
    Fig 32: Installing Differential Bearing Cups & Differential Case
    G03434830Courtesy of FORD MOTOR CO.
  35. Install the differential bearing cups and the differential case in the differential housing.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential case in place.
    36. CAUTION: Do not tighten the bolts to specification at this time.
    Fig 33: Identifying Differential Bearing Cap Bolts
    G03434831Courtesy of FORD MOTOR CO.
  36. Install the differential bearing caps in their original positions.
    1. Position the differential bearing caps.
    2. Install the bolts hand-tight.
  37. Remove the special tools.
  38. Tighten the bolts.
    • Tighten to 61 Nm (45 lb-ft).
    Fig 34: Tightening Differential Bearing Cap Bolts
    G03434832Courtesy of FORD MOTOR CO.
  39. Verify that the differential case rotates freely.
  40. Using the special tools, measure the backlash at 3 equally spaced points on the differential ring gear.
    1. Mount the special tool.
    2. Position the special tool.
    3. Zero the indicator.
    4. Turn the differential ring gear without turning the pinion gear. Record the measurement.
      • The backlash tolerance is 0.13 mm (0.005 in) to 0.20 mm (0.008 in) and cannot vary more than 0.05 mm (0.002 in) between points checked.
      • If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.
    Fig 35: Measuring Backlash At 3 Points On Differential Ring Gear
    G03434833Courtesy of FORD MOTOR CO.
  41. Remove the special tools.
    Fig 36: Removing Special Tools
    G03434834Courtesy of FORD MOTOR CO.
  42. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  43. Verify an acceptable pattern check. For additional information, refer to DIAGNOSIS & TESTING  .
  44. Install the RH axle shaft.
    45. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.
    CAUTION: Install the differential housing cover within 15 minutes of applying the silicone material.
    CAUTION: Allow the sealant to cure for 1 hour before filling the axle with lubricant.
    Fig 37: Applying Continuous Bead Of Sealant To Differential Housing Cover Mounting Surface
    G03434835Courtesy of FORD MOTOR CO.
  45. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
  46. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 29 Nm (21 lb-ft).
  47. Install the axle assembly. For additional information, refer to AXLE ASSEMBLY - FRONT  .
  48. Fill the axle with 1.54 liters (3.25 pints) of lubricant.
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