Differential Bearings: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Press the left and right differential bearing on the differential assembly.
1. Position the differential bearings.
2. Using the special tool, press the differential bearings on the differential assembly.
Fig 1: Pressing Differential Bearings On Differential Assembly
Courtesy of FORD MOTOR CO.
Position the special tool and the inner and outer bearing cups in their respective bores.
1. After placing the inner and outer bearing cups in their respective bores, place the special tool of the inner bearing cup.
2. Place the special tool on the outer bearing cup.
3. Install the special tool.
Fig 2: Positioning Special Tool And Inner And Outer Bearing Cups In Their Respective Bores
Courtesy of FORD MOTOR CO.
Tighten the special tool to seat the pinion bearing cups in their bores.

Fig 3: Tightening Special Tool To Seat Pinion Bearing Cups In Their Bores
Courtesy of FORD MOTOR CO.

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 4: Checking Differential Pinion Bearing Cups Are Correctly Seated

Courtesy of FORD MOTOR CO.

Make sure the differential pinion bearing cups are correctly seated.

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 5: Assembling And Position Drive Pinion Depth Gauge Set

Courtesy of FORD MOTOR CO.

Assemble and position the drive pinion depth gauge set.
1. Position the screw.
2. Position the aligning adapter.
3. Position the gauge disc.
4. Position the gauge block.
5. Position the inner drive pinion bearing.
6. Position the outer drive pinion bearing.
7. Thread on the handle and tighten.
  - Tighten to 2.2 Nm (20 lb-in).

NOTE: The gauge block must be offset to obtain an accurate reading.

Fig 6: Rotating Gauge Block Several Half Turns

Courtesy of FORD MOTOR CO.

Rotate the gauge block several half turns to make sure of correct seating of the drive pinion bearings and position the gauge block.
Install the special tool.
1. Position the gauge tube and the paper shipping tabs.
2. Install the differential bearing caps.
3. Install the differential bearing cap bolts.
  - Tighten to 105 Nm (77 lb-ft).
Fig 7: Installing Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Drive pinion bearing adjustment shims must be flat and clean.

NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between gauge block and gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.

Fig 8: Driving Pinion Bearing Adjustment Shim

Courtesy of FORD MOTOR CO.

Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
- After the correct drive pinion bearing adjustment shim thickness has been determined, remove all of the special tools.
Using the special tool and a shop press, drive the inner drive pinion bearing and drive pinion bearing adjustment shim until they are firmly seated on the pinion shaft.

Fig 9: Driving Inner Drive Pinion Bearing And Drive Pinion Bearing Adjustment Shim Seated On Pinion Shaft
Courtesy of FORD MOTOR CO.
Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.

Fig 10: Installing A New Drive Pinion Collapsible Spacer On Pinion Shaft Against Pinion Shaft Shoulder
Courtesy of FORD MOTOR CO.
Install the drive pinion assembly into the axle housing.

Fig 11: Installing Drive Pinion Assembly Into Axle Housing
Courtesy of FORD MOTOR CO.
Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
Using the special tool, install the drive pinion seal.

Fig 12: Installing Drive Pinion Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install the drive pinion flange.

Fig 13: Installing Drive Pinion Flange
Courtesy of FORD MOTOR CO.

CAUTION: Do not, under any circumstance, loosen the drive pinion nut to reduce pinion bearing preload. If it is necessary to reduce the preload, install a new drive pinion collapsible spacer and drive pinion nut.

CAUTION: Remove the special tool while taking rotational pinion bearing preload checks with the Nm (inch-pound) torque wrench.

Fig 14: Tightening Pinion Nut

Courtesy of FORD MOTOR CO.

Use the special tool to hold the pinion flange while tightening the pinion nut.
- Rotate the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload checks by rotating the differential pinion with a Nm (inch-pound) torque wrench. Tighten the pinion nut in small increments to avoid excessive pinion bearing preload. Tighten the pinion nut until the drive pinion bearing preload is in specification.
Place the differential carrier assembly with the new differential carrier bearing cups in the axle housing.

Fig 15: Placing Differential Carrier Assembly With New Differential Carrier Bearing Cups In Axle Housing
Courtesy of FORD MOTOR CO.
Install a differential bearing shim on the LH side.

Fig 16: Installing A Differential Bearing Shim On LH Side
Courtesy of FORD MOTOR CO.

NOTE: Apply pressure toward the LH side to make sure the left differential bearing cup is seated. Install the LH differential bearing cap and loosely.

Fig 17: Installing LH Differential Bearing Cap And Bolts

Courtesy of FORD MOTOR CO.

Install the differential bearing cap bolts.
Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected can be inserted by hand.

Fig 18: Installing Progressively Larger Differential Bearing Shims On RH Side
Courtesy of FORD MOTOR CO.
Install the RH side differential bearing cap and tighten the differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).
Fig 19: Installing RH Side Differential Bearing Cap And Bolts
Courtesy of FORD MOTOR CO.
Rotate the differential assembly to make sure it rotates freely.

Fig 20: Checking Differential Assembly Rotates Freely
Courtesy of FORD MOTOR CO.
Install the special tools and measure the ring gear backlash.
- If the backlash is within specification, proceed to Step 25.
- If a zero backlash condition occurs, proceed to Step 23.
- If the backlash is not within specification, proceed to Step 24.
Fig 21: Measuring Ring Gear Backlash
Courtesy of FORD MOTOR CO.
If a zero backlash condition occurs, add 0.50 mm (0.020 in) to the RH side shim and subtract 0.50 mm (0.020 in) from the LH side shim to allow a backlash indication. Go back to Step 22.
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. When the backlash is within specifications, proceed to Step 25.

Fig 22: Backlash Specifications Table
Courtesy of FORD MOTOR CO.

DIFFERENTIAL SHIM SIZE CHART 4067

Fig 23: Differential Shim Size Chart 4067
Courtesy of FORD MOTOR CO.
Rotate the differential assembly several times to make sure the differential bearings are seated.

Fig 24: Checking Differential Bearings Are Seated
Courtesy of FORD MOTOR CO.
Using the special tools, recheck the ring gear backlash.

Fig 25: Checking Ring Gear Backlash
Courtesy of FORD MOTOR CO.
Remove the differential bearing cap bolts and differential bearing caps.
To establish differential bearing preload, increase both LH and RH differential bearing shim sizes as shown.

Fig 26: Increasing Both LH And RH Differential Bearing Shim Sizes
Courtesy of FORD MOTOR CO.
Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.

Fig 27: Seating Differential Bearing Shims
Courtesy of FORD MOTOR CO.
Install the differential bearing caps and differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).
Fig 28: Installing Differential Bearing Caps And Bolts
Courtesy of FORD MOTOR CO.
Using the special tools, recheck the backlash.
Apply marking compound and rotate the differential assembly 5 complete revolutions.
Verify an acceptable pattern check.
Install the axle shafts. For additional information, refer to AXLE SHAFT .
Position the driveshaft and align the index marks on the pinion flange.

Fig 29: Positioning Driveshaft And Align Index Marks On Pinion Flange
Courtesy of FORD MOTOR CO.

CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.

Fig 30: Installing Driveshaft Flange Bolts

Courtesy of FORD MOTOR CO.

Install the driveshaft flange bolts.
- Tighten to 103 Nm (76 lb-ft).