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Disassembly And Assembly: Axle: Assembly

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    NOTE: To ease installation, coat the seal axle tube mating surfaces with lubricant.
  1. Using the special tools, install the axle shaft oil seals.
    • Use special tools 205-428, 205-427 (LH), and 205-426 (RH) to install the axle shaft oil seals.
    • Place the axle shaft oil seals onto the tool, and position the assembly into the differential housing. Lengthen the tool as necessary until both seals start evenly in the axle tubes. Continue to lengthen the tool until both step plates bottom out against the housing.
      Fig 1: Installing Axle Shaft Oil Seals
      G03919285Courtesy of FORD MOTOR CO.
  2. Place the special tool on the differential case hubs, and position the assembly into the differential housing.
    • Use special tool 205-D047.
      Fig 2: Placing Special Tool On Differential Case Hubs
      G03919286Courtesy of FORD MOTOR CO.
    3. NOTE: Use a dial indicator with a minimum travel capacity of 5.08 mm (0.200 inch).
    NOTE: Repeat this step until there is a consistent reading.
  3. Determine the total thickness of differential bearing shims to install on the differential case hubs, less the preload, which is calculated later in this procedure. Record this measurement as the total case end play.
    1. Position the special tool.
    2. Position the special tool.
      • Locate the tip of the tool on a flat surface of one of the ring gear bolt spot faces.
    3. Force the ring gear as far as possible toward the special tool.
    4. With the pressure still applied, zero the special tool.
    5. Force the ring gear as far as it will go in the opposite direction.
    6. Record the reading.
      Fig 3: Forcing Ring Gear As Far As Possible Toward Special Tool
      G03919205Courtesy of FORD MOTOR CO.
      Fig 4: Forcing Ring Gear As Far As It Will Go In Opposite Direction
      G03919144Courtesy of FORD MOTOR CO.
  4. Remove the differential case with the special tool from the differential housing.
    • Do not remove the special tool from the differential case hubs.
      Fig 5: Removing Differential Case With Special Tool From Differential Housing
      G03919286Courtesy of FORD MOTOR CO.
  5. Install the inner oil baffle and the inner and outer pinion bearing cups.
    1. Position the oil baffle and the bearing cups in the differential housing.
    2. Place the special tools on the inner and outer bearing cups.
      • Place special tool 205-006 B1 on the outer pinion bearing cup.
      • Place special tool 205-006 B2 on the inner pinion bearing cup.
    3. Install and tighten special tool 205-098 to seat the cups.
    • Remove the special tools after seating the cups.
      Fig 6: Positioning Inner Oil Baffle And Inner And Outer Pinion Bearing Cups
      G03919146Courtesy of FORD MOTOR CO.
      Fig 7: Installing Inner And Outer Pinion Bearing Cups
      G03919209Courtesy of FORD MOTOR CO.
    6. NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.
    Fig 8: Checking Clearance Between Cup And Bore
    G03878664Courtesy of FORD MOTOR CO.
  6. Check that the cups have seated correctly in their bores.
    7. CAUTION: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.
    NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.
  7. Assemble and position the following in the differential housing.
    1. Position the adapter for 205-S156.
    2. Position the adapter for 205-S127.
    3. Position the inner pinion bearing.
    4. Position the adapter for 205-S127.
    5. Position the adapter for 205-S156.
    6. Position the outer pinion bearing.
    7. Thread on the adapter for 205-S127.
      Fig 9: Assembling Pinion Bearings & Special Tools
      G03883577Courtesy of FORD MOTOR CO.
    8. NOTE: This step simulates pinion bearing preload.
    Fig 10: Tightening Special Tool
    G03919212Courtesy of FORD MOTOR CO.
  8. Using a Nm (lb-in) torque wrench, tighten the special tool to the specification.
    9. NOTE: Offset the special tool to obtain an accurate reading.
    Fig 11: Rotating Special Tool
    G03883649Courtesy of FORD MOTOR CO.
  9. Rotate the special tool several half-turns to seat the pinion bearings. Position the special tool as shown.
  10. Install the special tool.
    1. Position the special tool.
      • Use tool 205-D033.
    2. Install the bearing caps.
    3. Install the bolts.
      • Tighten to 108 Nm (80 lb-ft).
        Fig 12: Installing Special Tool
        G03919296Courtesy of FORD MOTOR CO.
    11. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring device.
    NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.
  11. Using a feeler gauge or flat, clean drive pinion position shims, measure the gap between the special tools. Record the measurement.
    • Remove the special tools after making the correct shim selection.
      Fig 13: Identifying Drive Pinion Bearing Adjustment Shim
      G03878604Courtesy of FORD MOTOR CO.
    12. NOTE: The differential ring gear and pinion is only available in a matched set. Matching numbers etched on both the differential ring gear and pinion are for verification. If installing a new differential ring gear and pinion, verify these numbers match before proceeding with assembly. The end of the pinion with the etched figures is the "button" end.
    NOTE: Use the gear contact pattern method to verify the final pinion position is valid. For additional information, refer to CHECKING TOOTH CONTACT PATTERN AND CONDITION OF THE RING AND PINION .
  12. Shim the pinion as follows:
    • Etched on the button end of each pinion is a zero (0), or a plus (+) or minus (-) with a number. This number indicates the best running position for each particular differential ring gear. Shimming behind the inner pinion bearing controls this dimension.
      Fig 14: Identifying Numbers On Pinion & Ring Gear
      G03883411Courtesy of FORD MOTOR CO.
  13. If reusing the old differential ring gear and pinion, proceed as follows:
    • Measure and record the old drive pinion position shim thickness and select a new shim of the same dimension.
    • To change the pinion adjustment, drive pinion position shims are available in the thickness shown in the following charts. Measure each shim separately with a micrometer.
    DRIVE PINION POSITION SHIMS THICKNESS SPECIFICATION

    mm Inches
    1 22 0.048
    1.27 0.050
    1.32 0.052
    1.37 0.054
    1.42 0.056
    1.47 0.058
    1.52 0.060
    1.57 0.062
  14. If installing a new differential ring gear and pinion, notice the (+) or (-) etching on both the old and new pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures.
    • For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 inch) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 inch) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 inch) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 inch) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
    15. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  15. Install the correct thickness drive pinion position shim on the pinion.
  16. Using the special tools, install the differential pinion bearing.
    • Use an axle bearing/seal plate, special tool 205-092, and a suitable press to install the differential pinion bearing.
      Fig 15: Installing Differential Pinion Bearing
      G03919299Courtesy of FORD MOTOR CO.
  17. Using a suitable driver, install the pinion seal.
    • Lightly coat the pinion seal lip with lubricant.
      Fig 16: Installing Pinion Seal
      G04643595Courtesy of FORD MOTOR CO.
  18. Install a new collapsible spacer.
    Fig 17: Installing New Collapsible Spacer
    G03919137Courtesy of FORD MOTOR CO.
    19. CAUTION: Do not damage the pinion, the bearings, the seal or the cup.
    Fig 18: Inserting Pinion Into Differential Housing
    G03919158Courtesy of FORD MOTOR CO.
  19. Insert the pinion into the differential housing, and seat the inner bearing into the bearing cup.
    20. 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 while holding the backside of the drive pinion.
    NOTE: If reusing the original pinion and flange, align the index marks made during disassembly.
    Fig 19: Installing Flange With New Washer And Nut
    G03919090Courtesy of FORD MOTOR CO.
  20. Lightly coat the flange splines and seal mating area with lubricant, then install the flange with a new washer and nut.
    21. CAUTION: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.
  21. Tighten the nut.
    • Use the special tool to prevent the flange from turning while tightening the nut. Remove the special tool when taking pinion bearing torque preload readings.
    • Rotate the pinion occasionally to verify that the bearings are seating correctly.
    • Take frequent pinion bearing torque preload readings.
      • If installing new differential pinion bearings, tighten the pinion nut to specifications. For additional information, refer to SPECIFICATIONS .
      • If installing the original pinion bearings, the final reading must be 0.56 Nm (5 lb-in) more than the initial reading taken during disassembly.
        Fig 20: Tightening Nut
        G03919131Courtesy of FORD MOTOR CO.
        Fig 21: Checking Pinion Bearing Torque Preload
        G03919085Courtesy of FORD MOTOR CO.
  22. Position the differential case with the special tool into the differential housing.
    • Use special tool 205-D047.
      Fig 22: Positioning Differential Case With Special Tool Into Differential Housing
      G03919286Courtesy of FORD MOTOR CO.
    23. NOTE: Repeat this step until there is a consistent reading.
  23. Determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.
    1. Position the special tool.
    2. Position the special tool.
    3. Force the ring gear into mesh with the pinion.
      • Rock the ring gear to allow the teeth of the gears to mesh.
    4. With the pressure still applied, zero the special tool.
    5. Force the ring gear away from the pinion.
    6. Record the reading.
      Fig 23: Forcing Ring Gear Into Mesh With The Pinion
      G03919163Courtesy of FORD MOTOR CO.
      Fig 24: Forcing The Ring Gear Away From The Pinion
      G03919164Courtesy of FORD MOTOR CO.
  24. Remove the differential case with the special tool from the differential housing.
    • Remove the special tool from the differential case.
      Fig 25: Removing Special Tool From Differential Case
      G03919286Courtesy of FORD MOTOR CO.
  25. Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case. Differential bearing shims are available in the thickness shown in the following chart.
    • For example, a reading of 1.14 mm (0.045 inch), requires that 1.14 mm (0.045 inch) shims be placed on the ring gear side of the differential case.
      DIFFERENTIAL BEARING SHIMS THICKNESS SPECIFICATION

      mm Inches
      0.076 0.003
      0.127 0.005
      0.254 0.010
      0.762 0.030
  26. Using the special tool(s), install the differential bearing.
    • Use special tool 205-D044 to install the differential bearing.
      Fig 26: Installing Differential Bearing (1 Of 2)
      G03919310Courtesy of FORD MOTOR CO.
  27. Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
    • Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 inch) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
  28. Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
  29. Using the special tools, install the differential bearing.
    1. Place the special tool under the bearing to protect it during the bearing installation.
      • Use special tool 205-D018.
    2. Using the special tool(s), install the bearing.
      • Use special tool 205-D044 to install the differential bearing.
        Fig 27: Installing Differential Bearing (2 Of 2)
        G03883589Courtesy of FORD MOTOR CO.
  30. Position the differential bearing cups on the bearings.
    Fig 28: Positioning Differential Bearing Cups On Bearings
    G03919168Courtesy of FORD MOTOR CO.
    31. CAUTION: Install the C-clamp at the 12 and 6 o'clock positions to allow the horizontal spread of the housing.
    CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Do not damage the ring gear and pinion.
    NOTE: Use a C-clamp with a minimum 15 inch opening and a 16,250 lb. load limit.
  31. Using a C-clamp, spread the differential housing 0.38 mm (0.015 in).
    • Use a soft face hammer to seat the differential into the differential housing.
      • Remove the C-clamp after seating the differential in the differential housing.
        Fig 29: Spreading Differential Housing Using C-Clamp
        G03919169Courtesy of FORD MOTOR CO.
    32. CAUTION: Match the positioning of the mating letters on the bearing caps and the differential housing.
  32. Install the bearing caps.
    • Tighten to 108 Nm (80 lb-ft).
      Fig 30: Installing Bearing Caps
      G04414224Courtesy of FORD MOTOR CO.
  33. Using the special tools, measure backlash at 3 equally spaced points.
    • The backlash must be within the specifications, and cannot vary more than 0.05 mm (0.002 in) between points checked. A backlash variation or more than 0.05 mm (0.002 in) indicates gear/case runout.
      • Make the necessary corrections by moving shims from one side of the differential case to the other, until the correct backlash adjustment is achieved.
        • Correct for high backlash by moving the ring gear toward the pinion.
        • Correct for low backlash by moving the ring gear away from the pinion.
          Fig 31: Measuring Differential Ring Gear Backlash
          G03912927Courtesy of FORD MOTOR CO.
  34. Check the gear tooth contact pattern. For additional information, refer to CHECKING TOOTH CONTACT PATTERN AND CONDITION OF THE RING AND PINION  .
    Fig 32: Checking Gear Tooth Contact Pattern
    G03878431Courtesy of FORD MOTOR CO.
    35. CAUTION: Clean the differential housing cover mounting surfaces with a suitable solvent, to remove all traces of oil film or foreign material.
    NOTE: The differential housing cover requires the use of silicone sealant material rather than a gasket.
    NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.
    Fig 33: Applying Silicone Rubber Sealer To Differential Housing Cover
    G04414153Courtesy of FORD MOTOR CO.
  35. Apply the specified bead of silicone rubber sealer as shown.
    36. CAUTION: Allow one hour curing time before filling the axle with lubricant.
    NOTE: Place 2 cover bolts into the differential housing cover at the 2 o'clock and 8 o'clock positions. This will help to position the differential housing cover onto the differential housing.
  36. Install the differential housing cover.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 34: Identifying Differential Housing Cover Bolt
      G03883433Courtesy of FORD MOTOR CO.
  37. Install the axle shaft assemblies and the front wheel hubs. For additional information, refer to WHEEL HUB .
  38. Fill the axle with the specified type and quantity of lubricant.
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