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Differential Ring And Pinion: Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Always install new drive pinion bearings when installing new drive pinion bearing cups.
  1. Install new drive pinion bearing cups.
    • Using the special tools, install the drive pinion bearing cups.
      Fig 1: Installing Drive Pinion Bearing Cups
      G03944444Courtesy of FORD MOTOR CO.
  2. Assemble and position the following in the differential housing.
    1. Position the screw.
    2. Position the aligning adapter.
    3. Position the inner pinion bearing.
    4. Position the gauge disc.
    5. Position the gauge block.
    6. Position the outer pinion bearing.
    7. Thread on the handle.
      Fig 2: Assembling Inner/Outer Pinion Bearing And Special Tools In Differential Housing
      G03944445Courtesy of FORD MOTOR CO.
  3. Using a Nm torque wrench, tighten the handle.
    • Tighten to 2.5 Nm (22 lb-in).
      Fig 3: Tightening Handle
      G03944446Courtesy of FORD MOTOR CO.
    4. NOTE: Offset the Gauge Block to obtain an accurate reading.
    Fig 4: Seating Pinion Bearing
    G03912895Courtesy of FORD MOTOR CO.
  4. Rotate the Gauge Block several half turns to make sure the pinion bearings seat correctly. Position the special tool as shown in Fig 4.
  5. 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 differential bearing cap bolts.
      • Tighten to 61 Nm (45 lb-ft).
        Fig 5: Installing Special Tool And Paper Shipping Tags
        G03912896Courtesy of FORD MOTOR CO.
    6. NOTE: Selection of a drive pinion position shim that is too thick results in deep tooth contact at final assembly. Do not attempt to force the feeler gauge or drive pinion position shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.
  6. 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 drive pinion position shim thickness.
      Fig 6: Inserting Shim
      G03912975Courtesy of FORD MOTOR CO.
  7. Select the correct thickness drive pinion position shim.
    • New drive pinion position shims are available in the following sizes:
      DRIVE PINION POSITION SHIMS THICKNESS

      mm inch
      1.35 0.053
      1.40 0.055
      1.45 0.057
      1.50 0.059
      1.55 0.061
      1.60 0.063
      1.65 0.065
      1.70 0.067
      1.75 0.069
      1.80 0.071
      1.85 0.073
    • Notice the plus (+), minus (-) or zero (0) etching on the new drive pinion, and adjust the thickness of the new drive pinion position shim. If etching is plus (+), subtract the number from the gauged drive pinion position shim thickness. If etching is minus (-), add the number to the gauged drive pinion position shim thickness.
      Fig 7: Identifying Marks On Drive Pinion
      G03913090Courtesy of FORD MOTOR CO.
  8. Install the drive pinion position shim and the inner pinion bearing.
    • Using the special tool and a suitable press, seat the inner pinion bearing firmly against the drive pinion position shim.
      Fig 8: Installing Pinion Position Shim And Differential Pinion Bearing
      G03912899Courtesy of FORD MOTOR CO.
  9. Install a new collapsible spacer.
    Fig 9: Installing Collapsible Spacer
    G03912978Courtesy of FORD MOTOR CO.
  10. Install the outer drive pinion bearing and the drive pinion oil slinger.
    Fig 10: Identifying Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
    G03884436Courtesy of FORD MOTOR CO.
    11. NOTE: Lubricate the drive pinion oil seal lips with rear axle lubricant.
    NOTE: The drive pinion oil seal must be fully seated all the way around or drive pinion oil seal damage will occur.
    Fig 11: Installing Drive Pinion Oil Seal
    G03912902Courtesy of FORD MOTOR CO.
  11. Using the special tool, install the drive pinion oil seal.
  12. Lubricate the drive pinion gear splines with rear axle lubricant.
  13. Install the drive pinion gear into the axle housing.
    Fig 12: Positioning Pinion Gear In Differential Housing
    G03912903Courtesy of FORD MOTOR CO.
    14. 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
    G03912904Courtesy of FORD MOTOR CO.
  14. Position the pinion flange.
  15. Using the special tool, install the pinion flange.
    Fig 14: Installing Pinion Flange
    G03944382Courtesy of FORD MOTOR CO.
    16. CAUTION: Do not loosen the pinion nut to reduce pinion bearing preload. Install a new collapsible spacer and pinion nut if pinion bearing preload reduction is necessary.
  16. Using the special tool to hold the pinion flange, tighten the pinion nut to set the pinion bearing preload.
    • Tighten the pinion nut, rotating the pinion occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing preload readings by rotating the pinion with a Nm torque wrench. The final reading must be 1.7-3.4 Nm (15-30 lb-in).
      Fig 15: Identifying Pinion Flange Holding Tool
      G03944376Courtesy of FORD MOTOR CO.
  17. Install the special tools.
    Fig 16: Installing Special Tool
    G03912907Courtesy of FORD MOTOR CO.
  18. Install the differential assembly in the differential housing.
    Fig 17: Installing Differential Case In Differential Housing
    G03912986Courtesy of FORD MOTOR CO.
    19. NOTE: Repeat this step until obtaining a consistent reading.
  19. Measure the total end play.
    1. Install the special tool.
    2. Force the differential assembly 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 assembly 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 in this procedure.
      Fig 18: Measuring Total End Play
      G03912987Courtesy of FORD MOTOR CO.
  20. Remove the special tool, then remove the differential assembly.
    1. Remove the special tool.
    2. Remove the differential assembly.
      Fig 19: Installing Special Tool
      G03912910Courtesy of FORD MOTOR CO.
    21. CAUTION: Do not reuse the original differential ring gear bolts.
  21. Using a suitable press, install the differential ring gear.
    1. Position the differential ring gear and the differential assembly. Start 2 or 3 new differential ring gear bolts to align the holes in the differential ring gear and the differential assembly.
    2. Using a suitable press, install the differential ring gear.
      Fig 20: Installing Differential Ring Gear
      G03972119Courtesy of FORD MOTOR CO.
  22. Install the remaining new differential ring gear bolts.
    • Tighten to 122 Nm (90 lb-ft).
      Fig 21: Identifying Differential Ring Gear Bolts
      G03912912Courtesy of FORD MOTOR CO.
  23. Install the special tool and position the differential assembly in the differential housing.
    1. Install the special tool.
    2. Position the differential assembly in the differential housing.
      Fig 22: Installing Special Tool
      G03912991Courtesy of FORD MOTOR CO.
  24. Position the special tool.
    Fig 23: Positioning Special Tool
    G03912917Courtesy of FORD MOTOR CO.
  25. 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: Setting Special Dial Indicator Tool
    G03912915Courtesy of FORD MOTOR CO.
  26. 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 in this procedure.
    Fig 25: Forcing Differential Ring Gear Away From Pinion Gear
    G03912916Courtesy of FORD MOTOR CO.
  27. Remove the special tool.
    Fig 26: Positioning Special Tool
    G03912917Courtesy of FORD MOTOR CO.
  28. Remove the differential assembly from the differential housing. Remove the special tools from the differential assembly hubs.
    Fig 27: Removing Differential Case From Differential Housing
    G03912996Courtesy of FORD MOTOR CO.
  29. Complete the worksheet and select the appropriate thickness differential bearing shims. New differential bearing shims are available in 0.0762 mm (0.003 in), 0.127 mm (0.005 in), 0.254 mm (0.010 in) and 0.762 mm (0.030 in) thickness.
    DIFFERENTIAL BEARING SHIM SELECTION PROCEDURE WORKSHEET

    Line Item Result (actual) mm (in) Result (example) mm (in)
    A Total end play measurement (without gears)   2.032 (0.080)
    B Add preload +0.2032 (+0.008) +0.2032 (+0.008)
    C Total (add A and B)   2.2352 (0.088)
    D End play measurement (with gears)   1.0414 (0.041)
    E Subtract the initial backlash allowance from the differential ring gear side -0.0762 (-0.003) -0.0762 (-0.003)
    F Difference (subtract E from D) (thickness of shims to place on the differential ring gear side)   0.9652 (0.038)
    G Difference (subtract F from C) (thickness of shims to place on the drive pinion side)   1.27 (0.050)
  30. Install the differential bearing shims and the differential bearing.
    1. Position the differential bearing shims and the differential bearing.
    2. Using a suitable press, install the differential bearing.
      • Repeat this step for opposite side of the differential assembly.
      • Most axles will have the larger amount of shims on the differential ring gear side and the smaller amount on the case side.
        Fig 28: Installing Differential Bearing Shims And Differential Bearing
        G03912919Courtesy of FORD MOTOR CO.
  31. Install the special tools.
    • Position the clutch housing gauge needle in the differential carrier spreader adapter hole.
      Fig 29: Positioning Clutch Housing Gauge Needle In Differential Carrier Spreader Adapter Hole
      G03912998Courtesy of FORD MOTOR CO.
    32. CAUTION: Overspreading can damage the differential housing.
    Fig 30: Spreading Differential Housing
    G03912921Courtesy of FORD MOTOR CO.
  32. Spread the differential housing to the specification.
  33. Remove the special tools.
    Fig 31: Identifying Special Tools
    G03913000Courtesy of FORD MOTOR CO.
    34. NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the differential housing.
  34. Install the differential bearing cups and the differential assembly in the differential housing.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential assembly in place.
      Fig 32: Installing Differential Bearing Cups And Differential Assembly In Differential Housing
      G03912923Courtesy of FORD MOTOR CO.
    35. CAUTION: Do not tighten the differential bearing cap bolts to specification at this time.
  35. Install the differential bearing caps in their original positions.
    1. Position the differential bearing caps.
    2. Install the differential bearing cap bolts hand-tight.
      Fig 33: Identifying Differential Bearing Caps
      G03912924Courtesy of FORD MOTOR CO.
  36. Remove the special tools.
  37. Tighten the differential bearing cap bolts.
    • Tighten to 61 Nm (45 lb-ft).
      Fig 34: Locating Differential Bearing Cap Bolts
      G03912925Courtesy of FORD MOTOR CO.
  38. Verify that the differential assembly rotates freely.
  39. 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 Differential Ring Gear Backlash
        G03912926Courtesy of FORD MOTOR CO.
  40. Remove the special tools.
    Fig 36: Measuring Differential Ring Gear Backlash
    G03912927Courtesy of FORD MOTOR CO.
  41. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  42. Verify an acceptable pattern check. For additional information, refer to DIAGNOSIS AND TESTING .
  43. Install the RH axle shaft.
    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: Applying Sealant To Differential Housing Cover Mounting Surface
    G03912929Courtesy of FORD MOTOR CO.
  44. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
  45. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 29 Nm (21 lb-ft).
  46. Install the axle assembly. For additional information, refer to AXLE ASSEMBLY .
  47. Fill the axle with Motorcraft SAE 80W-90 Premium Rear Axle Lubricant to 9.56 mm (0.38 in) below the bottom of the filler hole.
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