Differential Ring and Pinion: 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.
- Position the special tool and the inner and outer drive pinion bearing cups in their respective bores.
- After placing the inner and outer drive pinion bearing cups in their bores, place the special tool (inner) on the inner drive pinion bearing cup.
- Place the special tool (outer) on the outer drive pinion bearing cup.
- Install the special tool.
- Tighten the special tool to seat the drive pinion bearing cups into their bores.
- Make sure the drive pinion bearing cups are correctly seated in their bores.
- Assemble and position the special tools.
- Tighten the special tool.
- Tighten to 2.2 Nm (20 lb-in).
- Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings and position the special tool.
- Install the special tool.
- Position the special tool.
- Install the differential bearing caps.
- Install the 4 differential bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).
- 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 the selected drive pinion bearing adjustment shim until they are firmly seated on the pinion shaft.
- Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
- Install the drive pinion assembly into the axle housing.
- Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
- Using the special tools, install the drive pinion seal.
- Using the special tools, install the drive pinion flange.
- 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.
- Using the special tool, install the new differential bearings.
- Install the differential ring gear bolts.
- Tighten to 105 Nm (77 lb-ft).
- Position the differential carrier assembly and the new differential bearing cups in the differential housing.
- Install a differential bearing shim of the shown dimension on the left side.
- Install the LH bearing cap and loosely install the bolts.
- Install progressively larger differential bearing shims on the RH side until the largest shim is installed by hand.
- Install the right side bearing cap and bolts. Tighten the LH and RH bearing cap bolts.
- Tighten to 105 Nm (77 lb-ft).
- Rotate the differential carrier several times to verify the differential bearings have seated correctly.
- Install the special tools and measure the ring gear backlash.
- If a zero backlash condition occurs, add 0.50 mm (0.020 in) to the RH hand side shim and subtract 0.50 mm (0.020 in) from the LH side shim to allow a backlash indication. Go back to Step 24.
- 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 specification, proceed to Step 27.
DIFFERENTIAL SHIM SIZE CHART 4067
- Remove the bearing cap bolts and bearing caps.
- To establish differential bearing preload, increase both LH and RH differential bearing shim size by the thickness shown.
- Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
- Install the bearing caps and bolts.
- Tighten to 105 Nm (77 lb-ft).
- Using the special tools, recheck the ring gear 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 .
- Clean the gasket mating surface of the axle and the differential housing cover.
- Apply a new, continuous bead of sealant to the differential housing cover.
- Install the differential housing cover and the differential housing cover bolts.
- Tighten to 45 Nm (33 lb-ft).
- Fill the axle to the level shown with axle lubricant and install the filler plug.
- Tighten to 30 Nm (22 lb-ft).
- Position the driveshaft and align the index marks on the pinion flange.
- Install the driveshaft flange bolts.
- Tighten to 103 Nm (76 lb-ft).
NOTE:
If a feeler gauge can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not 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.
NOTE:
This step duplicates final drive pinion bearing preload.
NOTE:
The special tool must be offset to obtain an accurate reading.
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 the gauge block and the 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.
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.
NOTE:
Apply stud and bearing mount to the differential ring gear bolts.
CAUTION:
Always install the bearing caps in their original locations and positions.
NOTE:
Apply pressure toward the LH side to make sure the left differential bearing cup seats correctly.
CAUTION:
Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.
NOTE:
The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured.
CAUTION:
For Traction-Lok® axles, first fill the axle with 118 ml (4 ounces) of friction modifier.
NOTE:
Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.
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.