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Differential Bearings - Rear Axle: Installation

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the special tool, install the differential drive pinion bearing cups.
    1. Position the bearing cups on the special tool.
    2. Position the special tool and the differential drive pinion bearing cups in the differential housing.
    3. Tighten the special tool to fully seat the differential drive pinion bearing cups in the bores.
    Fig 1: Installing Differential Drive Pinion Bearing Cups
    G03190328Courtesy of FORD MOTOR CO.
    2. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.
    Fig 2: Measuring Feeler Gauge Of Between Cup And Bottom
    G03190329Courtesy of FORD MOTOR CO.
  2. Make sure the differential pinion bearing cups are correctly seated.
    3. NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.
    Fig 3: Installing Drive Pinion Bearings And Special Tools
    G03190330Courtesy of FORD MOTOR CO.
  3. Install the drive pinion bearings and special tools as shown.
    4. NOTE: This step duplicates drive pinion bearing preload.
    Fig 4: Tightening Nut
    G03190331Courtesy of FORD MOTOR CO.
  4. Thread the special tool onto the screw and tighten to the specification shown.
    • Tighten to 2.2 Nm (20 lb-in).
    5. CAUTION: Position the adapter so it does not contact the housing.
    CAUTION: Offset the special tool to obtain an accurate reading.
    Fig 5: Rotating Special Tool Several Half Turns To Seat Drive Pinion Bearings
    G03190332Courtesy of FORD MOTOR CO.
  5. Rotate the special tool several half turns to seat the drive pinion bearings. Position the special tool as shown.
  6. Install the special tool.
    1. Position the special tool on the differential housing differential bearing seat.
    2. Install the differential bearing caps.
    3. Install the differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    Fig 6: Installing Differential Bearing Cap Bolts
    G03190333Courtesy of FORD MOTOR CO.
  7. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the gauge block and the gauge tube. A slight drag indicates correct shim selection.
    • Notice the plus (+), minus (-) or zero (0) paint marking on the drive pinion stem and adjust the thickness of the new shim. If the marking is plus (+), subtract the number from the gauged shim thickness. If the marking is minus (-), add the number to the gauged shim thickness.
    Fig 7: Checking Drive Pinion Bearing Adjustment Shim
    G03190334Courtesy of FORD MOTOR CO.
  8. Remove all of the special tools.
    9. CAUTION: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.
  9. Position the drive pinion bearing adjustment shim and the inner pinion bearing on the drive pinion gear stem.
  10. Using the special tools and a suitable press, firmly seat the drive pinion bearing adjustment shim and inner pinion bearing on the drive pinion gear stem.
    Fig 8: Positioning Drive Pinion Bearing
    G03190335Courtesy of FORD MOTOR CO.
    11. CAUTION: Make sure the splines on the drive pinion gear stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth.
    Fig 9: Installing Differential Drive Pinion Collapsible Spacer
    G03190336Courtesy of FORD MOTOR CO.
  11. Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the pinion stem shoulder.
  12. Install the outer pinion bearing and the drive pinion oil seal slinger.
    Fig 10: Installing Outer Pinion Bearing And Drive Pinion Oil Slinger
    G03190337Courtesy of FORD MOTOR CO.
    13. CAUTION: Installation without the correct tool can result in early drive pinion seal failure.
    CAUTION: If the drive pinion seal becomes misaligned during installation, remove it and install a new drive pinion seal.
    NOTE: Coat the drive pinion seal lips with grease.
    Fig 11: Installing New Drive Pinion Seal Using Special Tool
    G03190338Courtesy of FORD MOTOR CO.
  13. Using the special tool, install the new drive pinion seal.
  14. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential housing.
    Fig 12: Installing Differential Drive Pinion In Differential Housing
    G03190339Courtesy of FORD MOTOR CO.
  15. Position the pinion flange.
    1. Lubricate the pinion flange splines with grease.
    2. Align the pinion flange.
    Fig 13: Aligning Pinion Flange
    G03190340Courtesy of FORD MOTOR CO.
  16. Using the special tool, install the pinion flange.
    Fig 14: Installing Pinion Flange Using Special Tool
    G03190341Courtesy of FORD MOTOR CO.
    17. CAUTION: Do not, under any circumstance, loosen the pinion nut to reduce drive pinion bearing preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut.
    CAUTION: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.
    Fig 15: Holding Pinion Flange And Tightening Pinion Nut Using Special Tool
    G03190342Courtesy of FORD MOTOR CO.
  17. Use the special tool to hold the pinion flange while tightening the pinion nut.
    • Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench.
  18. Tighten the pinion nut to set the drive pinion bearing preload. Refer to the TORQUE SPECIFICATION  for drive pinion bearings in the Specifications.
    Fig 16: Tightening Pinion Nut
    G03190343Courtesy of FORD MOTOR CO.
  19. Press the left and right differential bearing on the differential assembly.
    1. Position the differential bearing.
    2. Using the special tool, press the differential bearing on the differential assembly.
    Fig 17: Installing Differential Bearing
    G03190344Courtesy of FORD MOTOR CO.
  20. Install the differential assembly.
    Fig 18: Installing Differential Assembly
    G03190345Courtesy of FORD MOTOR CO.
  21. Install a differential bearing shim of the thickness shown on the LH side of the differential case.
    Fig 19: Installing Differential Bearing Shim (LH) Side
    G03190346Courtesy of FORD MOTOR CO.
    22. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
    Fig 20: Installing Bearing Cap Bolts
    G03190347Courtesy of FORD MOTOR CO.
  22. Install the left bearing cap and loosely install the bearing cap bolts.
    23. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
    Fig 21: Installing Differential Bearing Shims On Right Side
    G03190348Courtesy of FORD MOTOR CO.
  23. Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.
  24. Install the right bearing cap and bolts.
  25. Tighten the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 22: Tighten The 4 Differential Bearing Cap Bolts
    G03190349Courtesy of FORD MOTOR CO.
  26. Rotate the differential case to make sure it turns freely.
    Fig 23: Rotating Differential Case To Ensure It Turns Freely
    G03190350Courtesy of FORD MOTOR CO.
  27. Install the special tool at the 12 o'clock position.
    Fig 24: Installing Special Tool At 12 O'Clock Position
    G03190351Courtesy of FORD MOTOR CO.
  28. Using the special tools, measure the differential ring gear backlash at 4 equally spaced points.
    1. Attach the special tool.
    2. Position the special tool tip centrally on a drive tooth.
    3. Zero the indicator.
    4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.203 mm (0.008 in) to 0.305 mm (0.012 in) and must not vary more than 0.101 mm (0.004 in) between points measured. A backlash variation of more than 0.101 mm (0.004 in) between points checked indicates gear/case runout.
      • To correct for a high or low backlash, proceed as follows.
    Fig 25: Measuring Differential Ring Gear Backlash
    G03190352Courtesy of FORD MOTOR CO.
  29. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash.
    BACKLASH CHANGE

    Backlash Change Required Thickness Change Required
    mm in mm in
    0.025 0.001 0.050 0.002
    0.050 0.002 0.050 0.002
    0.076 0.003 0.101 0.004
    0.101 0.004 0.152 0.006
    0.127 0.005 0.152 0.006
    0.152 0.006 0.203 0.008
    0.177 0.007 0.254 0.010
    0.203 0.008 0.254 0.010
    0.228 0.009 0.304 0.012
    0.254 0.010 0.355 0.014
    0.279 0.011 0.355 0.014
    0.304 0.012 0.406 0.016
    0.330 0.013 0.457 0.018
    0.335 0.381 0.014 0.015 0.457 0.508 0.018 0.020

    Differential Shim Size Chart - 4067 - 

    NUMBERS OF STRIPES

    Numbers of Stripes and Color Code Dimension A
    mm in
    2 - C-COAL 7.7978-7.8105 0.3070-0.3075
    1 - C-COAL 7.7470-7.7597 0.3050-0.3055
    5 - BLU 7.6962-7.7089 0.3030-0.3035
    4 - BLU 7.6454-7.6581 0.3010-0.3015
    3 - BLU 7.5946-7.6073 0.2990-0.2995
    2 - BLU 7.5458-7.5565 0.2970-0.2975
    1 - BLU 7.493-7.505 0.2950-0.2955
    5 - PINK 7.4422-7.4549 0.2930-0.2935
    4 - PINK 7.3914-7.4041 0.2910-0.2915
    3 - PINK 7.3406-7.3533 0.2890-0.2895
    2 - PINK 7.2898-7.3025 0.2870-0.2875
    1 - PINK 7.2390-7.2517 0.2850-0.2855
    5 - GRN 7.1882-7.2009 0.2830-0.2835
    4 - GRN 7.1374-7.1501 0.2810-0.2815
    3 - GRN 7.0866-7.0993 0.2790-0.2795
    2 - GRN 7.0358-7.0485 0.2770-0.2775
    1 - GRN 6.9850-7.0485 0.2750-0.2755
    5 - WH 6.9342-6.9469 0.2730-0.2735
    4 - WH 6.8834-6.8961 0.2710-0.2715
    3 - WH 6.8326-6.8453 0.2690-0.2695
    2 - WH 6.7818-6.7945 0.2670-0.2675
    1 - WH 6.7310-6.7437 0.2650-0.2655
    5 - YEL 6.6802-6.6929 0.2630-0.2635
    4 - YEL 6.6294-6.6421 0.2610-0.2615
    3 - YEL 6.5786-6.5913 0.2590-0.2595
    2 - YEL 6.5278-6.5405 0.2570-0.2575
    1 - YEL 6.4770-6.4897 0.2550-0.2555
    5 - ORNG 6.4262-6.4389 0.2530-0.2535
    4 - ORNG 6.3754-6.3881 0.2510-0.2515
    3 - ORNG 6.3246-6.3373 0.2490-0.2495
    2 - ORNG 6.2738-6.2865 0.2470-0.2475
    1 - ORNG 6.2223-6.2357 0.2450-0.2455
    2 - RED 1 - RED 6.1722-6.1849 6.1214-6.1341 0.2430-0.2435 0.2410-0.2415
  30. Remove the 4 differential bearing cap bolts.
    • Remove the differential assembly.
    Fig 26: Removing Differential Bearing Cap Bolts
    G03190353Courtesy of FORD MOTOR CO.
  31. Measure the thickness of the selected right and left bearing shims.
  32. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 in).
    33. CAUTION: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, the aluminum housing can be damaged.
    Fig 27: Placing Differential Bearing Shims In Differential Housing
    G03190354Courtesy of FORD MOTOR CO.
  33. Place the differential bearing shims in the differential housing.
  34. Install the special tools.
    Fig 28: Installing Special Tools
    G03190355Courtesy of FORD MOTOR CO.
    35. CAUTION: Overspreading may damage the differential housing.
    NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final dial indicator reading.
    Fig 29: Spreading Differential Housing
    G03190356Courtesy of FORD MOTOR CO.
  35. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the screw until spreading the differential housing to the specification.
    3. Remove the special tool.
  36. Install the differential assembly.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential assembly in place between the differential bearing shims.
    Fig 30: Installing Differential Assembly
    G03190357Courtesy of FORD MOTOR CO.
    37. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.
    Fig 31: Installing Differential Bearing Caps
    G03190358Courtesy of FORD MOTOR CO.
  37. Install the differential bearing caps and the differential bearing cap bolts in their original locations and positions.
  38. Loosen and remove the special tool.
    Fig 32: Removing Special Tool
    G03190359Courtesy of FORD MOTOR CO.
  39. Tighten the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 33: Tightening Differential Bearing Cap Bolts
    G03190360Courtesy of FORD MOTOR CO.
  40. Install the special tool at the 12 o'clock position.
    Fig 34: Installing Special Tool At 12 O'Clock Position
    G03190361Courtesy of FORD MOTOR CO.
  41. Using the special tools, recheck the ring gear backlash.
    Fig 35: Measuring Ring Gear Backlash
    G03190362Courtesy of FORD MOTOR CO.
  42. Apply marking compound and rotate the differential assembly 5 complete revolutions.
    Fig 36: Rotating Differential Assembly
    G03190363Courtesy of FORD MOTOR CO.
  43. Verify an acceptable pattern check. For additional information, refer to CHECKING TOOTH CONTACT PATTERN AND CONDITION OF THE RING AND PINION .
    44. 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: Identifying Silicone Gasket
    G03190364Courtesy of FORD MOTOR CO.
  44. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
    • Use silicone gasket and sealant.
  45. Install the differential housing cover.
  46. Fill the axle assembly with the specified lubricant.
  47. Install the rear axle assembly. For additional information, refer to REAR AXLE ASSEMBLY .
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