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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 284 (Front Drive Axle/Differential - DANA 35) >> Disassembly And Assembly >> Axle >> Assembly

Disassembly And Assembly: Axle: Assembly

WARNING: This page is about a different car, the 2003 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Always install new gaskets and seals when assembling the axle. When building the subassembly, lubricate each component with clean Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A. Also, lubricate the subassembly when installing it into the differential housing. Tighten all fasteners to specification.
    CAUTION: Always install new differential pinion bearings when installing new differential drive pinion bearing cups.
  1. Lubricate the new differential drive pinion bearing cups.
    • Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
  2. Using the special tools, install the differential drive pinion bearing cups.
    Fig 1: Installing Differential Drive Pinion Bearing Cups
    G01291787Courtesy of FORD MOTOR CO.
    3. NOTE: Apply a light film of oil to the differential pinion bearings before installing them.
  3. Assemble and position the following in the differential housing.
    1. Position the Screw.
    2. Position the Aligning Adapter.
    3. Position the inner differential pinion bearing.
    4. Position the Gauge Disc.
    5. Position the Gauge Block.
    6. Position the outer differential pinion bearing.
    7. Thread on the Handle.
      Fig 2: Assembling Differential Housing Components
      G01291788Courtesy of FORD MOTOR CO.
  4. Using a Nm (pound-inch) torque wrench, tighten the Handle.
    Fig 3: Tightening Handle
    G01291789Courtesy of FORD MOTOR CO.
    5. NOTE: Offset the Gauge Block to obtain an accurate reading.
    Fig 4: Rotating Gauge Block Several Half Turns To Ensure Differential Pinion Bearings Seat Correctly
    G01291790Courtesy of FORD MOTOR CO.
  5. Rotate the Gauge Block several half turns to ensure the differential pinion bearings seat correctly, and position the Gauge Block as shown.
  6. 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 bolts.
      Fig 5: Installing Special Tool & Paper Shipping Tags
      G01291791Courtesy of FORD MOTOR CO.
    7. NOTE: Use a feeler gauge, or flat, clean drive pinion position shims as a measuring device.
    NOTE: Selection of a shim that is too thick results in deep tooth contact at final assembly. Do not attempt to force the gauge or shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.
  7. 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 shim thickness.
      Fig 6: Determining Correct Shim Thickness
      G01291792Courtesy of FORD MOTOR CO.
  8. Select the correct thickness drive pinion position shim.
    • New drive pinion position shims are available in 0.762 mm (0.030 in), 0.8128 mm (0.032 in), 0.8636 mm (0.034 in), 0.9144 mm (0.036 in), 0.9652 mm (0.038 in), 1.016 mm (0.040 in), 1.0668 mm (0.042 in), 1.1176 mm (0.044 in), 1.1684 mm (0.046 in), 1.2192 mm (0.048 in), 1.27 mm (0.050 in), and 1.3208 mm (0.052 in) thickness.
  9. The shim selection tool steps identify the correct shim for a ring and pinion with an "O" etching. Optimum depth for each gearset is determined at the factory and the number is etched, + or -, on the pinion button. If the etched number is positive, subtract that number from the shim thickness identified by the selection tool steps. If the number is negative, add that number to the selected shim thickness.
    Fig 7: Identifying Etched Number
    G01291793Courtesy of FORD MOTOR CO.
  10. Install the pinion position shim and the differential pinion bearing.
    • Using the special tool and a suitable press, seat the differential pinion bearing firmly against the pinion position shim.
      Fig 8: Installing Pinion Position Shim & Differential Pinion Bearing
      G01291794Courtesy of FORD MOTOR CO.
  11. Install a new collapsible spacer.
    Fig 9: Installing Collapsible Spacer
    G01291795Courtesy of FORD MOTOR CO.
  12. Install the differential pinion bearing and the front axle drive pinion shaft oil slinger.
    Fig 10: Installing Differential Pinion Bearing & Front Axle Drive Pinion Shaft Oil Slinger
    G01291796Courtesy of FORD MOTOR CO.
    13. CAUTION: Installing the pinion seal without the correct tool can result in early seal failure.
    CAUTION: If the pinion seal becomes cocked during installation, remove it and install a new one.
    Fig 11: Installing Pinion Seal
    G01291797Courtesy of FORD MOTOR CO.
  13. Using the special tool, install the pinion seal.
  14. Lightly lubricate the pinion gear splines.
    • Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
  15. Position the pinion gear in the differential housing.
    Fig 12: Positioning Pinion Gear In Differential Housing
    G01291798Courtesy of FORD MOTOR CO.
    16. 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: Installing Pinion Flange
    G01291799Courtesy of FORD MOTOR CO.
  16. Align the index marks and install the pinion flange.
  17. Install the new nut hand-tight.
    Fig 14: Installing Nut
    G01291800Courtesy of FORD MOTOR CO.
    18. CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.
  18. Use the special tool to hold the pinion flange while tightening the nut to set the preload.
    • Rotate the pinion occasionally to ensure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
      • If installing new differential pinion bearings, tighten the nut to specification. Refer to SPECIFICATIONS .
      • If installing the original differential pinion bearings, the final reading must be 0.56 Nm (5 lb-in) more than the initial reading taken during disassembly.
        Fig 15: Using Special Tool To Hold Pinion Flange While Tightening Nut To Set Preload
        G01291801Courtesy of FORD MOTOR CO.
  19. Install the special tool.
    Fig 16: Installing Special Tool
    G01291802Courtesy of FORD MOTOR CO.
  20. Install the differential case in the differential housing.
    Fig 17: Installing Differential Case In Differential Housing
    G01291803Courtesy of FORD MOTOR CO.
    21. NOTE: Repeat this step until obtaining a consistent reading.
  21. Measure the total end play.
    1. Install the special tool.
    2. Force the differential case 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 case 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. See Fig 29.
      Fig 18: Measuring Total End Play
      G01291804Courtesy of FORD MOTOR CO.
  22. Remove the special tool, and remove the differential case.
    1. Remove the special tool.
    2. Remove the differential case.
      Fig 19: Removing Differential Case
      G01291805Courtesy of FORD MOTOR CO.
  23. Use a fine flat file to remove any burrs and nicks found on the differential ring gear mounting surface.
    Fig 20: Using Fine Flat File To Remove Any Burrs & Nicks Found On Differential Ring Gear Mounting Surface
    G01291806Courtesy of FORD MOTOR CO.
    24. CAUTION: Do not reuse the original bolts.
  24. Using a suitable press, install the differential ring gear.
    1. Position the differential ring gear and the differential case. Start two or three new bolts to align the holes in the ring gear and the differential case.
    2. Using a suitable press, install the differential ring gear.
      Fig 21: Installing Differential Ring Gear
      G01291807Courtesy of FORD MOTOR CO.
  25. Install the remaining new bolts. Tighten all of the bolts to specification.
    Fig 22: Installing Bolts
    G01291808Courtesy of FORD MOTOR CO.
  26. Install the special tool, and position the assembly in the differential housing.
    1. Install the special tool.
    2. Position the assembly in the differential housing.
      Fig 23: Installing Special Tool & Positioning Assembly In Differential Housing
      G01291809Courtesy of FORD MOTOR CO.
  27. Position the special tool.
    Fig 24: Positioning Special Tool
    G01291810Courtesy of FORD MOTOR CO.
  28. Force the differential ring gear into mesh with the pinion gear (zero backlash). With force still applied, set the special tool to zero.
    Fig 25: Forcing Differential Ring Gear Into Mesh With Pinion Gear
    G01291811Courtesy of FORD MOTOR CO.
  29. 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. See Fig 29.
    Fig 26: Forcing Differential Ring Gear Away From Pinion Gear As Far As Possible
    G01291812Courtesy of FORD MOTOR CO.
  30. Remove the special tool.
    Fig 27: Removing Special Tool
    G01291813Courtesy of FORD MOTOR CO.
  31. Remove the differential case from the differential housing. Remove the special tool from the differential case hubs.
    Fig 28: Removing Differential Case From Differential Housing
    G01291814Courtesy of FORD MOTOR CO.
  32. Complete the worksheet, and select the appropriate thickness differential shims. New differential 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.
    Fig 29: Differential Bearing Shim Selection Procedure Worksheet
    G01291815Courtesy of FORD MOTOR CO.
  33. Install the differential shims and the differential bearing.
    1. Position the differential shims and the differential bearing.
    2. Using a suitable press, install the differential bearing.
      • Repeat this step for opposite side of the differential case.
        Fig 30: Installing Differential Shims & Differential Bearing
        G01291816Courtesy of FORD MOTOR CO.
  34. Install the special tools.
    • Position the Clutch Housing Alignment Adapter needle in the Housing Spreader Adapter hole.
      Fig 31: Positioning Clutch Housing Alignment Adapter Needle In Housing Spreader Adapter Hole
      G01291817Courtesy of FORD MOTOR CO.
    35. CAUTION: Over spreading can damage the differential housing.
    Fig 32: Spreading Differential Housing
    G01291818Courtesy of FORD MOTOR CO.
  35. Spread the differential housing to the specification.
  36. Remove the special tools.
    Fig 33: Removing Special Tools
    G01291819Courtesy of FORD MOTOR CO.
    37. NOTE: Push the differential case downward to fully seat the differential bearing cups in the differential housing.
  37. Install the differential bearing cups and the differential case in the differential housing.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential case in place.
      Fig 34: Installing Differential Bearing Cups & Differential Case In Differential Housing
      G01291820Courtesy of FORD MOTOR CO.
    38. CAUTION: Do not tighten the bolts to specification at this time.
  38. Install the differential bearing caps in their original positions.
    1. Position the differential bearing caps.
    2. Install the bolts hand-tight.
      Fig 35: Installing Differential Bearing Caps
      G01291821Courtesy of FORD MOTOR CO.
  39. Remove the special tools.
    Fig 36: Removing Special Tools
    G01291822Courtesy of FORD MOTOR CO.
  40. Tighten the bolts.
    Fig 37: Tightening Bolts
    G01291823Courtesy of FORD MOTOR CO.
  41. Verify that the differential case rotates freely.
  42. Using the special tools, measure the backlash at three 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. A backlash variation of more than 0.005 mm (0.002 in) indicates gear/case runout.
      • 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 38: Measuring Backlash At Points On Differential Ring Gear
        G01291824Courtesy of FORD MOTOR CO.
  43. Remove the special tools.
    Fig 39: Removing Special Tools
    G01291825Courtesy of FORD MOTOR CO.
  44. Check the gear tooth contact pattern. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION article.
    Fig 40: Checking Gear Tooth Contact Pattern
    G01291826Courtesy of FORD MOTOR CO.
  45. Using the special tools, install the axle tube bearing.
    Fig 41: Installing Axle Tube Bearing
    G01291827Courtesy of FORD MOTOR CO.
  46. Using the special tools, install the axle shaft oil seal.
    Fig 42: Installing Axle Shaft Oil Seal
    G01291828Courtesy of FORD MOTOR CO.
  47. Using the special tools, install the axle shaft bearing.
    Fig 43: Installing Axle Shaft Bearing
    G01291829Courtesy of FORD MOTOR CO.
  48. Using the special tools, install the axle shaft oil seal.
    Fig 44: Installing Axle Shaft Oil Seal
    G01291830Courtesy of FORD MOTOR CO.
  49. Install the axle shaft.
    Fig 45: Installing Axle Shaft
    G01291831Courtesy of FORD MOTOR CO.
    50. CAUTION: The machined mating surfaces on the differential housing and the differential housing cover must be clean and free of lubricant before applying the new silicone sealant. Cover the inside of the differential housing before cleaning the machined surface to prevent contamination.
  50. Clean the differential housing and the differential housing cover mating surfaces.
  51. Apply a continuous bead of sealant to the differential housing cover.
    • Use Ford Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1.
      Fig 46: Applying Bead Of Sealant To Differential Housing Cover
      G01291832Courtesy of FORD MOTOR CO.
    52. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone or it will be necessary to apply new sealant. If possible, allow one hour before filling the axle with lubricant to make sure the silicone sealant has cured.
  52. Install the differential housing cover.
    1. Position the differential housing cover.
    2. Install the bolts.
      Fig 47: Installing Differential Housing Cover
      G01291833Courtesy of FORD MOTOR CO.
  53. Install the front axle assembly. For additional information, refer to AXLE ASSEMBLY-FRONT .
  54. Fill the axle with 1.54 Liter (2.25 pints) of lubricant.
    • Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
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