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Disassembly And Assembly: Axle: Assembly

WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not omit the pinion bearing oil baffle or bearing damage may occur.
    Fig 1: Positioning Drive Pinion Bearing Oil Baffle On Special Tool
    GF0003274Courtesy of FORD MOTOR CO.
  1. If removed, position the baffle on the special tool.
  2. Using the special tool, install the baffle.
    Fig 2: Installing Drive Pinion Bearing Oil Baffle Using Special Tool
    GF0003275Courtesy of FORD MOTOR CO.
  3. Using the special tool, install the bearing cups.
    Fig 3: Installing Drive Pinion Bearing Cups
    GF0003276Courtesy of FORD MOTOR CO.
    4. NOTE: You must use the pinion bearings assembled in this procedure step at final assembly.
    Fig 4: Positioning Pinion Bearings In Carrier Housing
    GF0003277Courtesy of FORD MOTOR CO.
  4. Assemble and position the special tools and the pinion bearings in the carrier housing.
    • Position the screw adapter.
    • Position the aligning adapter.
    • Position the pinion bearing.
    • Position the gauge disc adapter.
    • Position the gauge block adapter.
    • Position the pinion bearing.
    • Thread on the handle adapter.
    5. NOTE: This step duplicates final pinion bearing preload.
    Fig 5: Tightening Special Tool
    GF0003278Courtesy of FORD MOTOR CO.
  5. Tighten the special tool.
    • Tighten to 2.2 Nm (20 lb-in) rotational torque.
    6. NOTE: Offset the gauge block adapter to obtain an accurate reading.
    Fig 6: Rotating Gauge Block Adapter 45 Degrees
    GF0003315Courtesy of FORD MOTOR CO.
  6. Rotate the gauge block adapter several half-turns to make sure the pinion bearings seat correctly, and position the gauge block adapter.
  7. Install the special tool.
    • Position the special tool.
    • Install the 2 differential bearing caps.
    • Install the 4 bolts.
      • Tighten to 105 Nm (77 lb-ft).
    Fig 7: Installing Special Tool
    GF0003280Courtesy of FORD MOTOR CO.
    8. NOTE: Use only flat, clean drive pinion bearing adjustment shims.
    NOTE: Do not attempt to force the shim between the gauge block adapter and the gauge tube adapter. A slight drag indicates correct shim selection.
    Fig 8: Identifying Drive Pinion Bearing Adjustment Shims
    GF0003316Courtesy of FORD MOTOR CO.
  8. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • Check the adjustment shim thickness between the gauge block adapter and the gauge tube adapter.
    • After determining the correct shim thickness, remove the special tools.
    9. NOTE: You must use the same pinion bearings from the previous steps.
    Fig 9: Installing Drive Pinion Bearing
    GF0003282Courtesy of FORD MOTOR CO.
  9. Install the pinion bearing.
    • Place the selected drive pinion bearing adjustment shim on the pinion gear.
    • Using a suitable press and the special tool, press the pinion bearing until it is firmly seated on the pinion gear.
  10. Place a new drive pinion collapsible spacer on the pinion stem.
    Fig 10: Identifying Drive Pinion Collapsible Spacer
    GF0003269Courtesy of FORD MOTOR CO.
  11. Install the outer pinion bearing.
    Fig 11: Locating Outer Drive Pinion Bearing
    GF0003283Courtesy of FORD MOTOR CO.
  12. Install the slinger.
    Fig 12: Installing Drive Pinion Oil Slinger
    GF0003284Courtesy of FORD MOTOR CO.
    13. NOTE: Coat the lips of the pinion seal with front axle lubricant.
    Fig 13: Installing Drive Pinion Seal On Special Tool
    GF0003285Courtesy of FORD MOTOR CO.
  13. Place the pinion seal on the special tool.
  14. Place the special tool and seal in the pinion seal bore and drive the seal into place.
    Fig 14: Placing Special Tool In Pinion Seal Bore And Drive Seal
    GF0003228Courtesy of FORD MOTOR CO.
  15. Lightly lubricate the pinion gear splines with front axle lubricant.
  16. Position the drive pinion in the housing.
    Fig 15: Locating Drive Pinion Gear
    GF0000840Courtesy of FORD MOTOR CO.
    17. CAUTION: Never install the drive pinion U-joint flange with a hammer or power tools or damage to the component may occur.
    NOTE: Disregard the scribe marks if installing a new flange.
    Fig 16: Positioning U-Joint Flange On Drive Pinion
    GF0003286Courtesy of FORD MOTOR CO.
  17. Align the index marks and position the U-joint flange on the drive pinion.
  18. Using the special tool, install the drive pinion U-joint flange.
    Fig 17: Installing Drive Pinion U-Joint Flange Using Special Tool
    GF0003229Courtesy of FORD MOTOR CO.
    19. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut.
    Fig 18: Holding Pinion Flange Using Special Tool
    G03928261Courtesy of FORD MOTOR CO.
  19. Install the special tool and tighten the pinion nut. For additional information, refer to the torque specifications in the Specifications portion of this section.
    • Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a N.m (inch-pound) torque wrench.
  20. Install the ring gear.
    • Place the ring gear on the differential assembly.
    • Position 3 bolts to align the holes in the ring gear and the differential case.
    • Using a suitable press, position the ring gear.
    • Press the ring gear into place.
    Fig 19: Measuring Record Pinion Bearing Preload
    GF0003224Courtesy of FORD MOTOR CO.
    Fig 20: Pressing Differential Ring Gear Into Place
    G03884443Courtesy of FORD MOTOR CO.
  21. Install the 10 new ring gear bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 21: Identifying Differential Ring Gear Bolts
    G03878612Courtesy of FORD MOTOR CO.
    22. CAUTION: Press against the bearing inner core only.
    Fig 22: Installing Differential Bearings
    G03878661Courtesy of FORD MOTOR CO.
  22. Using a suitable press and the special tool, install the 2 differential bearings.
    • Position the differential bearing.
    • Using a suitable press and the special tool, install the differential bearing.
    • Repeat the procedure for the other differential bearing.
  23. Position the differential case assembly.
    • Position the differential bearing cups on the differential bearings.
    • Lower the differential case assembly in place.
    Fig 23: View Of Differential Bearing Cups On Differential Bearings
    G03928292Courtesy of FORD MOTOR CO.
  24. Install the differential bearing shim of the thickness shown on the LH side of the differential bearing.
    Fig 24: Identifying Differential Bearing Shim Of Specific Thickness
    GF0003287Courtesy of FORD MOTOR CO.
    25. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated.
    Fig 25: Locating Left Bearing Cap
    GF0003288Courtesy of FORD MOTOR CO.
  25. Install the left bearing cap and loosely install the 2 bearing cap bolts.
  26. Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.
    Fig 26: Install Thicker Differential Bearing Shims
    GF0003289Courtesy of FORD MOTOR CO.
  27. Install the right bearing cap and 2 bolts.
  28. Tighten the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 27: Identifying Differential Bearing Cap Bolts And Special Holding Fixture
    G04637391Courtesy of FORD MOTOR CO.
  29. Rotate the differential carrier to make sure it turns freely.
    Fig 28: Rotating Differential Assembly
    G03928297Courtesy of FORD MOTOR CO.
  30. Install the special tool.
    Fig 29: Installing Special Tool
    G03928309Courtesy of FORD MOTOR CO.
  31. Measure the ring gear backlash at 4 places to obtain a consistent reading.
    Fig 30: Measuring Differential Ring Gear Backlash Using Special Tools
    G03912927Courtesy of FORD MOTOR CO.
    32. NOTE: If the backlash is not within the specifications, correct it by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
    Fig 31: Installing Thicker Or Thinner Differential Bearing Shim To Increase Backlash
    GF0003317Courtesy of FORD MOTOR CO.
  32. To increase the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
  33. To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
    Fig 32: Installing Thicker Or Thinner Differential Bearing Shim To Decrease Backlash
    GF0003318Courtesy of FORD MOTOR CO.
  34. Remove the 4 differential bearing cap bolts and 2 bearing caps.
    • Remove the differential carrier.
    Fig 33: Identifying Differential Bearing Cap Bolts And Special Holding Fixture
    G04637391Courtesy of FORD MOTOR CO.
  35. Measure the thickness of the selected right and left bearing shims.
  36. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 in).
  37. Install the special tools.
    Fig 34: Installing Special Tools
    GF0003265Courtesy of FORD MOTOR CO.
    38. CAUTION: Overspreading may damage the differential housing.
    NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters, prior to taking the final dial indicator reading.
    Fig 35: Spreading Differential Housing To Specification
    GF0003266Courtesy of FORD MOTOR CO.
  38. Spread the differential housing to specification.
    1. Adjust the special tool to zero.
    • Tighten the screw until spreading the differential housing to specification.
    • Remove the special tools.
    39. CAUTION: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, the aluminum housing can be damaged.
    Fig 36: Placing Differential Bearing Shims In Differential Housing
    GF0003290Courtesy of FORD MOTOR CO.
  39. Place the differential bearing shims in the differential housing.
  40. Install the differential carrier.
    • Position the 2 differential bearing cups on the 2 differential bearings.
    • Lower the differential carrier in place between the 2 differential bearing shims.
      Fig 37: View Of Differential Bearing Cups On Differential Bearings
      G03928292Courtesy of FORD MOTOR CO.
    41. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.
    Fig 38: Installing Differential Bearing Caps And Differential Bearing Cap Bolts
    GF0003291Courtesy of FORD MOTOR CO.
  41. Install the 2 differential bearing caps and the 4 differential bearing cap bolts in their original locations and positions.
  42. Loosen and remove the special tool.
    Fig 39: Identifying Special Tool
    GF0003292Courtesy of FORD MOTOR CO.
  43. Tighten the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 40: Identifying Differential Bearing Cap Bolts And Special Holding Fixture
    G04637391Courtesy of FORD MOTOR CO.
  44. Rotate the differential carrier to make sure it turns freely.
    Fig 41: Rotating Differential Assembly
    G03928297Courtesy of FORD MOTOR CO.
  45. Install the special tool at the 12 o'clock position.
    Fig 42: Installing Special Tool
    G03928309Courtesy of FORD MOTOR CO.
  46. Using the special tools, recheck the ring gear backlash.
    Fig 43: Measuring Differential Ring Gear Backlash Using Special Tools
    G03912927Courtesy of FORD MOTOR CO.
  47. Apply marking compound and rotate the differential assembly 5 complete revolutions.
    Fig 44: Rotating Differential Assembly
    G03928297Courtesy of FORD MOTOR CO.
  48. Verify an acceptable pattern check. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION article.
    49. NOTE: Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber.
    NOTE: Install the axle housing tube within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has cured.
    Fig 45: Assembling Axle Housing Tube
    GF0003319Courtesy of FORD MOTOR CO.
  49. Assemble the axle housing tube.
    • Align the bolt holes and position the axle tube.
    • Position the axle identification tag.
    • Install the 4 bolts.
      • Tighten to 73 Nm (54 lb-ft).
  50. Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth.
    Fig 46: Checking Axle Shaft Oil Seal And Axle Shaft Bearing Surface For Damage
    GF0003320Courtesy of FORD MOTOR CO.
  51. Install a new retainer circlip on each axle shaft.
    Fig 47: Installing New Retainer Circlip On Each Axle Shaft
    GF0003294Courtesy of FORD MOTOR CO.
  52. Insert the axle shafts and engage them with the side gears.
    Fig 48: Engaging Axle Shafts With Side Gears
    GF0003295Courtesy of FORD MOTOR CO.
  53. Push in on the axle shafts until the retaining circlips expand in the side gears.
    Fig 49: Identifying Snap Rings
    GF0003262Courtesy of FORD MOTOR CO.
  54. Remove the axle assembly from the Holding Fixture and place it on the bench.
    55. NOTE: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has cured.
    Fig 50: Applying Sealant To Differential Housing Cover Mounting Surface
    GF0003296Courtesy of FORD MOTOR CO.
  55. Fill the sealing groove on the differential housing cover with silicone gasket and sealant.
  56. Install the differential housing cover and 10 differential housing cover bolts.
    • Tighten to 32 Nm (24 lb-ft).
    Fig 51: Identifying Differential Housing Cover Bolts
    GF0003260Courtesy of FORD MOTOR CO.
  57. Remove the fill plug, fill the differential carrier housing, and install the fill plug.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 52: Filling Differential Carrier Housing
    GF0003311Courtesy of FORD MOTOR CO.
  58. Install the front drive axle assembly. For additional information, refer to Axle Assembly  in this article.
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