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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1539 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> In-Vehicle Repair >> Differential Bearings >> Installation

Differential Bearings: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the inner and outer pinion bearing cups and the special tools in their respective axle housing bores.
    1. After placing the inner and outer pinion bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
    2. Place the special tool (outer) on the outer pinion bearing cup.
    3. Install the special tool (drawbar).
      Fig 1: Identifying Special Tool
      G04643497Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 2: Identifying Special Tool
    G04643498Courtesy of FORD MOTOR CO.
    3. NOTE: If the feeler gauge can fit between a pinion bearing cup and the bottom of its bore at any point around the pinion bearing cup, remove and reseat the pinion bearing cup.
    Fig 3: Checking Clearance Between Cup And Bore
    G03878664Courtesy of FORD MOTOR CO.
  3. Check that the pinion bearing cups have seated correctly in their bores.
  4. Install the original outboard spacers in the side from which they were removed.
    Fig 4: Identifying Outboard Spacers
    G03883404Courtesy of FORD MOTOR CO.
    5. NOTE: Remove all nicks, burrs and dirt from the differential carrier hubs to allow the differential bearings to rotate freely.
    Fig 5: Identifying Special Tool On Differential Carrier Hubs
    G04643501Courtesy of FORD MOTOR CO.
  5. Place the 0.762 mm (0.030 in) inboard shim and the special tool on the differential carrier hubs. Position the differential carrier into the axle housing.
    6. NOTE: Use a dial indicator with a minimum travel capability of 5.08 mm (0.200 in).
    Fig 6: Identifying Special Tool
    G04643502Courtesy of FORD MOTOR CO.
  6. Mount the special tools as shown. Locate the tip of special tool on the flat surface of one of the differential ring gear bolts.
    7. NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. Record the reading. This is the total differential bearing shim thickness required, less preload. The final calculation occurs later during assembly.
    Fig 7: Measuring Differential Carrier End Play
    G04643503Courtesy of FORD MOTOR CO.
  7. Force the differential carrier as far as possible toward the indicator. With force still applied, zero the indicator.
  8. Force the differential carrier as far as it will go in the opposite direction. Record the total differential carrier end play reading.
    Fig 8: Measuring Differential Carrier End Play
    G04643504Courtesy of FORD MOTOR CO.
  9. After making sure the reading is consistent, remove the differential carrier from the axle housing. Do not remove the special tools from the differential carrier at this time.
    10. NOTE: 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.
  10. Assemble and position the following in the differential housing.
    1. Position the special tool.
    2. Position the special tool.
    3. Position the inner pinion bearing.
    4. Position the special tool.
    5. Position the special tool.
    6. Position the outer pinion bearing.
    7. Thread on the special tool.
      Fig 9: Identifying Special Tool
      G04643505Courtesy of FORD MOTOR CO.
  11. Install the special tool.
    1. Install the 2 differential bearing caps.
    2. Install the 4 differential bearing cap bolts.
      • Tighten to 108 Nm (80 lb-ft).
        Fig 10: Identifying Special Tool
        G04643506Courtesy of FORD MOTOR CO.
    12. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.
  12. Inspect the drive pinion bearing preload shim for damage. Discard it if necessary. New drive pinion bearing preload shims are available in the thickness shown in the following chart.
    AVAILABLE INNER DRIVE PINION

    mm Inches
    0.36 0.014
    0.38 0.015
    0.41 0.016
    0.46 0.018
    0.51 0.020
    0.53 0.021
    0.56 0.022
    0.58 0.023
    0.76 0.030
    13. NOTE: Use a feeler gauge or flat, clean drive pinion position shim as a measuring device.
    NOTE: Do not attempt to force the gauge or drive pinion position shim between the special tools. A slight drag indicates a correct selection.
  13. Using a feeler gauge or flat, clean drive pinion position shim, measure between the special tools. Record the measurement.
    • Remove the special tools after making the correct drive pinion position shim selection.
      Fig 11: Removing Special Tools
      G04643507Courtesy of FORD MOTOR CO.
  14. Notice the (+) or (-) etching on the pinion and adjust the new shim thickness to compensate for the difference of these 2 figures. If so equipped, include the oil slinger thickness in the total measurement to correctly set pinion depth.
    • For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 in) 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 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
    15. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.
    NOTE: Position the selected pinion depth shim on the pinion shaft between the inner bearing and the pinion head.
    Fig 12: Locating Pinion Bearing
    G04643508Courtesy of FORD MOTOR CO.
  15. Using the special tools and a suitable press, install the pinion bearing.
  16. Install the outer pinion bearing and drive pinion oil slinger.
  17. Position the original pinion bearing preload shims on the pinion and install the pinion gear in the pinion gear bore from the rear of the housing.
    18. NOTE: The pinion flange must never be hammered on or installed with power tools.
    Fig 13: Identifying Special Tool
    G04643509Courtesy of FORD MOTOR CO.
  18. Using the special tool, install the pinion flange.
  19. Use the special tool to prevent the pinion flange from turning while installing the old washer and the pinion nut.
    • Tighten to 637 Nm (470 lb-ft).
      Fig 14: Holding Pinion Flange With Special Tool
      G03883491Courtesy of FORD MOTOR CO.
  20. Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 2.9-5.0 Nm (25-45 lb-in).
    • To increase the drive pinion bearing preload, remove drive pinion bearing preload shims. To decrease the drive pinion bearing preload, add drive pinion bearing shims.
      Fig 15: Checking Pinion Rotational Torque
      G03918456Courtesy of FORD MOTOR CO.
  21. While using the special tool to prevent the pinion flange from turning, remove and discard the old washer and pinion nut.
    Fig 16: Holding Pinion Flange With Special Tool
    G03883491Courtesy of FORD MOTOR CO.
  22. Using the special tool, remove the pinion flange.
    Fig 17: Removing Pinion Flange Using Special Tool
    G03878593Courtesy of FORD MOTOR CO.
    23. CAUTION: If the drive pinion seal becomes cocked during installation, remove and install a new one. Make sure the garter spring remains in place during assembly. If the spring is dislodged, a new drive pinion seal must be installed.
  23. Using a suitable driver, drive the pinion seal into the housing.
    • Coat the pinion seal (rubber lips) with axle lubricant.
      Fig 18: Driving Pinion Seal Into Housing Using Special Tool
      G04643595Courtesy of FORD MOTOR CO.
    24. NOTE: The pinion flange must never be hammered on or installed with power tools.
    Fig 19: Checking Pinion Rotational Torque
    G03918456Courtesy of FORD MOTOR CO.
  24. Using the special tool, install the pinion flange.
  25. Using the special tool, prevent the pinion flange from turning while installing the new washer and pinion nut.
    • Tighten to 637 Nm (470 lb-ft).
      Fig 20: Holding Pinion Flange With Special Tool
      G03883491Courtesy of FORD MOTOR CO.
  26. Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 0.6 Nm (5 lb-in) higher than previously recorded with the new pinion seal installed.
    Fig 21: Checking Pinion Rotational Torque
    G03918456Courtesy of FORD MOTOR CO.
  27. Position the differential carrier assembly with the special tools in the axle housing. Install the special tools and locate the tip of special tool on a flat surface.
    Fig 22: Identifying Special Tool
    G04643518Courtesy of FORD MOTOR CO.
    28. NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.
    Fig 23: Measuring Differential Case End Play
    G04643519Courtesy of FORD MOTOR CO.
  28. Force the differential case away from the drive pinion. With force still applied, set the indicator to zero.
  29. Force the differential ring gear into mesh with the pinion to obtain the indicator reading. Record the reading.
    Fig 24: Measuring Differential Case End Play
    G04643520Courtesy of FORD MOTOR CO.
  30. Remove the differential case from the differential housing.
  31. Remove the special tools from the differential case.
    • Make sure the inner bearing shims remain on the differential carrier hubs.
  32. Using the special tool, install the differential bearing and shim on the LH side of the differential case.
    Fig 25: Identifying Special Tool For Differential Bearing Installation
    G03883526Courtesy of FORD MOTOR CO.
  33. Using the special tools, install the differential bearing.
    1. Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
    2. Using the special tool, drive the differential bearing onto the hub.
      Fig 26: Identifying Special Tool
      G04643522Courtesy of FORD MOTOR CO.
  34. Assemble the differential bearing cups to the differential bearings.
  35. Place one outboard spacer of the necessary thickness, as determined from the previous measurement, on the LH side of the differential housing.
  36. Determine the correct outboard spacer thickness and place it on the differential case hub on the RH side.
    • To determine the correct spacer thickness, first, subtract the reading of the previous measurement from the total differential case end play reading. Then, add 0.25 mm (0.010 in) to this amount. This is the correct thickness spacer to place on RH side of the housing.
    37. CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.
  37. Using the special tools, spread the differential housing to the specification.
    • Use a rawhide hammer to seat the differential into the differential housing pocket.
      Fig 27: Using Special Tool To Spread Differential Housing
      G03918287Courtesy of FORD MOTOR CO.
    38. NOTE: Match the mating letters as noted during disassembly.
  38. Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
    • Tighten to 108 Nm (80 lb-ft).
      Fig 28: Locating Differential Bearing Caps
      G04414224Courtesy of FORD MOTOR CO.
  39. Confirm the total preload.
    • Using a Nm (lb-in) torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential carrier installed) with new bearings installed as recommended by the following:
      • 3.54 and 3.73 = 0.9 Nm (8 lb-in)
      • 4.10 and 4.56 = 0.8 Nm (7 lb-in)
      • 4.63 and 5.13 = 0.8 Nm (7 lb-in)
    • If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.
      Fig 29: Checking Pinion Rotational Torque
      G03918456Courtesy of FORD MOTOR CO.
  40. Using the special tools, measure the differential ring gear and pinion backlash at 3 equally spaced points.
    Fig 30: Measuring Differential Ring Gear & Pinion Backlash Using Special Tools
    G03918386Courtesy of FORD MOTOR CO.
  41. Carry out the tooth contact pattern check to verify that the final pinion position is correct. For additional information, refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
  42. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
    43. NOTE: Align the index marks made during removal.
  43. Connect the driveshaft and the axle flange and install the 4 bolts.
    • Tighten to 136 Nm (100 lb-ft).
      Fig 31: Locating Index-Mark On Driveshaft Flange & Pinion Flange
      G03884149Courtesy of FORD MOTOR CO.
  44. Clean the gasket mating surface of the axle and the differential housing cover.
    45. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone.
    Fig 32: Proper Application Of Sealant To Differential Housing Cover
    G03878622Courtesy of FORD MOTOR CO.
  45. Apply a continuous bead of sealant to the differential housing cover as shown.
  46. Install the differential housing cover and the 10 differential housing cover bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 33: Locating Differential Housing Cover Bolts
      G04643529Courtesy of FORD MOTOR CO.
    47. NOTE: If possible, allow an hour before filling with lubricant to make sure the silicone sealant has correctly cured.
  47. Fill the axle with the specified type and amount of fluid.
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