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Disassembly And Assembly: Axle: Assembly

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: To ease installation, coat the seal axle tube mating surfaces with lubricant.
  1. Using the special tools, 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
      G04644421
  2. Place the special tool on the differential case hubs and position the assembly into the differential housing.
    Fig 2: Placing Special Tool On Differential Case Hubs
    G04644422
    3. 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.
    • Force the ring gear as far as possible to the ring gear side and zero the special tool.
      Fig 3: Checking Thickness Of Differential Bearing Shims (1 Of 2)
      G04644423
    4. NOTE: Repeat this step until there is a consistent reading.
    Fig 4: Checking Thickness Of Differential Bearing Shims (2 Of 2)
    G04644424
  4. Force the ring gear as far as possible to the pinion gear side. Record this measurement as the total case end play.
  5. Remove the differential case and 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
      G04644425
    6. NOTE: Make sure the inner oil baffle is squarely under the inner pinion bearing cup.
  6. Install the inner oil baffle and the inner and outer pinion bearing cups.
  7. Using the special tools, install the pinion bearing cups.
    • 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.
    • Install and tighten special tool 205-098 to seat the cups.
      Fig 6: Installing Inner Oil Baffle And Inner And Outer Pinion Bearing Cups (1 Of 2)
      G04644426
    8. 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 7: Checking Clearance Between Cup And Bore
    G03878664
  8. Check that the cups have seated correctly in their bores.
    9. 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.
  9. Assemble and position the following in the differential housing in the following sequence:
    1. Position the adapter 205-160.
    2. Position the adapter 205-105.
    3. Position the inner pinion bearing.
    4. Position the adapter 205-125.
    5. Position the adapter 205-159.
    6. Position the outer pinion bearing.
    7. Thread on the adapter 205-111.
      Fig 8: Identifying Pinion Bearings & Special Tools
      G03883577
    10. NOTE: This step simulates pinion bearing preload.
  10. Using a Nm (lb-in) torque wrench, tighten the special tool to set the rotational torque.
    • Tighten to a rotational torque of 2.2 Nm (20 lb-in).
      Fig 9: Checking Differential Pinion Bearing Preload
      G03878601
    11. NOTE: Offset the special tool to obtain an accurate reading.
    Fig 10: Rotating Special Tool
    G03883649
  11. Rotate the special tool several half-turns to seat the pinion bearings. Position the special tool as shown.
  12. Install the special tool.
    1. Install the 2 bearing caps.
    2. Install the 4 bolts.
      • Tighten to 108 Nm (80 lb-ft).
        Fig 11: Rotating Special Tool For Correct Seating Of Pinion Bearings
        G04644431
    13. 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.
  13. 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 12: Installing Bearing Caps
      G04644432
    14. 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 DRIVELINE SYSTEM-GENERAL INFORMATION .
  14. Install the correct thickness drive pinion position shim on the pinion.
    • 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.
    • 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.
      Fig 13: Identifying Numbers On Pinion & Ring Gear
      G03883411
  15. 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.
    AVAILABLE DRIVE PINION POSITION SHIMS

    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
  16. Using the special tools, install the selected pinion bearing shim and the differential pinion bearing.
    Fig 14: Identifying Numbers On Pinion Gear
    G04644434
  17. Using a suitable driver, install the pinion seal.
    • Lightly coat the pinion seal lip with lubricant.
      Fig 15: Driving Pinion Seal Into Housing Using Special Tool
      G04643595
  18. Install a new collapsible spacer.
    Fig 16: Locating Collapsible Spacer
    G03919137
    19. CAUTION: Do not damage the pinion, the bearings, the seal or the cup.
    Fig 17: Installing Collapsible Spacer
    G04644437
  19. Insert the pinion into the differential housing, and seat the inner bearing into the bearing cup.
    20. NOTE: 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.
    Fig 18: Identifying Pinion Flange
    G03919090
  20. Lightly coat the flange splines and seal mating area with lubricant, then install the flange with a new washer and nut.
    21. NOTE: 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 19: Holding Pinion Flange With Special Tool
        G03919131
        Fig 20: Measuring Pinion Bearing Torque Preload
        G03919085
  22. Position the differential case with the special tool into the differential housing.
    Fig 21: Checking Pinion Bearing Torque Preload
    G04644441
    23. NOTE: Repeat this step until there is a consistent reading.
  23. Using the special tools, 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.
    • Force the ring gear away from the pinion and zero the special tool.
    • Force the ring gear into mesh with the pinion.
      • Rock the ring gear to allow the teeth of the gears to mesh.
    • Record the reading.
      Fig 22: Positioning Differential Case With Special Tool Into Differential Housing
      G04644442
  24. Remove the differential case with the special tool from the differential housing.
    Fig 23: Checking Total Thickness Of Differential Bearing Shims (1 Of 2)
    G04644443
  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 in), requires that 1.14 mm (0.045 in) shims be placed on the ring gear side of the differential case.
    AVAILABLE DIFFERENTIAL BEARING SHIMS

    mm Inch
    0.076 0.003
    0.127 0.005
    0.254 0.010
    0.762 0.030
  26. Using the special tool, install the selected differential bearing shim and the differential bearing.
    Fig 24: Checking Total Thickness Of Differential Bearing Shims (2 Of 2)
    G04644444
  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 in) 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 selected differential bearing shim and the differential bearing on the drive pinion side of the case.
    1. Place the special tool under the bearing to protect it during the bearing installation.
    2. Using the special tool(s), install the bearing.
      Fig 25: Installing Differential Bearing
      G03883589
  30. Position the differential bearing cups on the bearings.
    Fig 26: Installing Differential Bearing (1 Of 2)
    G04644446
    31. CAUTION: Do not spread the differential housing more than specified or damage to the housing can occur.
    NOTE: Install the C-clamp at the 12 and 6 o'clock positions to allow the horizontal spread of the housing.
    NOTE: Use a safety strap to keep the C-clamp from rotating.
    NOTE: Use a C-clamp with a minimum 15 inch opening and a 16,250 lb load limit.
  31. Using a C-clamp with the dial indicator, spread the differential housing 0.38 mm (0.015 in) and install the differential carrier.
    1. Remove the dial indicator after measuring the housing spread.
    2. Using a soft-faced hammer, seat the differential into the differential housing.
      • Remove the C-clamp after seating the differential in the differential housing.
        Fig 27: Installing Differential Bearing (2 Of 2)
        G04644447
    32. NOTE: Match the positioning of the mating letters on the bearing caps and the differential housing.
  32. Install the 2 bearing caps and 4 bolts.
    • Tighten to 108 Nm (80 lb-ft).
      Fig 28: Locating Differential Bearing Caps
      G04414224
  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 29: Measuring Differential Ring Gear Backlash Using Special Tools
      G03912927
  34. Check the gear tooth contact pattern. For additional information, refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
    35. NOTE: Clean the differential housing cover mounting surfaces with a suitable solvent to remove all traces of oil film or foreign material.
    NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.
    Fig 30: Locating Differential Housing Cover Sealant
    G04414153
  35. Apply the specified bead of silicone rubber sealer as shown.
    36. 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 and the 10 differential cover bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 31: Identifying Differential Housing Cover Bolt
      G03883433
  37. Position the driveshaft in the front axle flange. Install the 4 new flange bolts.
    • Tighten to 35 Nm (26 lb-ft).
  38. Install the axle shaft assemblies and the front wheel hubs. For additional information, refer to FRONT SUSPENSION - FOUR WHEEL DRIVE (4WD) .
    39. NOTE: If possible, allow one hour curing time before filling the axle with lubricant.
  39. Fill the axle with the specified type and quantity of lubricant.
    40. CAUTION: Make sure that the nut retainer cap is correctly positioned to allow for cotter pin installation. Do not tighten or loosen the nut to align the retainer cap with the cotter pin hole. Overtightening of the fasteners may result in premature failure of steering linkage components.
  40. Position the RH tie-rod and drag link. Install the tie-rod nut, retainer cap and new cotter pin.
    • Tighten to 115 Nm (85 lb-ft).
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