Axle-Front Drive: Assembly

WARNING: This page is about a different car, the 2002 Ford Pickup, 2001 Ford Pickup, and 2000 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; bearing failure can result

Fig 1: Positioning Baffle On Special Tool

Courtesy of FORD MOTOR CO.

If removed, position the baffle on the special tool.
Using the special tool, install the baffle.

Fig 2: Installing Baffle
Courtesy of FORD MOTOR CO.

NOTE: Always install new pinion bearings when installing new pinion bearing cups.

Lightly oil the new pinion bearing cups and pinion bearings with Motorcraft SAE75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A.
Using the special tool, install the bearing cups.

Fig 3: Installing Bearing Cups
Courtesy of FORD MOTOR CO.

NOTE: You must use the pinion bearings assembled in this procedure step at final assembly.

Assemble and position the special tools and the pinion bearings in the carrier housing.
1. Position the Screw.
2. Position the Aligning Adapter.
3. Position the pinion bearing.
4. Position the Gauge Disc.
5. Position the Gauge Block.
6. Position the pinion bearing.
7. Thread on the Handle.
  
  Fig 4: Assembling & Positioning Special Tools & Pinion Bearings In Carrier Housing
  Courtesy of FORD MOTOR CO.

NOTE: This step duplicates final pinion bearing preload.

Fig 5: Setting Pinion Bearing Preload

Courtesy of FORD MOTOR CO.

Tighten the special tool to the specification to simulate bearing preload.

NOTE: Offset the Gauge Block to obtain an accurate reading.

Fig 6: Ensuring Pinion Bearings Are Seated Correctly

Courtesy of FORD MOTOR CO.

Rotate the Gauge Block several half-turns to make sure the pinion bearings seat correctly, and position the Gauge Block.
Install the special tool.
1. Position the special tool.
2. Install the differential bearing caps.
3. Install the bolts.
  
  Fig 7: Installing Special Tool
  Courtesy of FORD MOTOR CO.

NOTE: Use only flat, clean drive pinion bearing adjustment shims.

NOTE: Selection of a shim that is too thick results in a deep tooth contact at final assembly of integral axle assemblies. Do not attempt to force the shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection.

Use a drive pinion bearing adjustment shim as a gauge for shim selection.
- Check the adjustment shim thickness between the Gauge Block and the Gauge Tube.
- After determining the correct shim thickness, remove the special tools.
  
  Fig 8: Using Drive Pinion Bearing Adjustment Shim As Gauge For Shim Selection
  Courtesy of FORD MOTOR CO.

NOTE: You must use the same pinion bearings from the previous steps.

Install the pinion bearing.
- Place the 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.
  
  Fig 9: Installing Pinion Bearings
  Courtesy of FORD MOTOR CO.
Place a new drive pinion collapsible spacer on the pinion stem.

Fig 10: Installing Drive Pinion Collapsible Spacer
Courtesy of FORD MOTOR CO.
Install the outer pinion bearing.

Fig 11: Installing Outer Pinion Bearing
Courtesy of FORD MOTOR CO.
Install the slinger.

Fig 12: Installing Slinger
Courtesy of FORD MOTOR CO.

NOTE: Coat the lips of the pinion seal with Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A.

Fig 13: Placing Pinion Seal On Special Tool

Courtesy of FORD MOTOR CO.

Place the pinion seal on the special tool.
Place the special tool and seal in the pinion seal bore and drive the seal into place.

Fig 14: Installing Pinion Seal
Courtesy of FORD MOTOR CO.
Lightly lubricate the pinion gear splines with Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A.
Position the pinion gear in the housing.

Fig 15: Positioning Pinion Gear In Housing
Courtesy of FORD MOTOR CO.

CAUTION: Never install the axle universal joint flange with a hammer.

NOTE: Disregard the scribe marks if installing a new flange.

Fig 16: Positioning Universal Joint Flange On Drive Pinion

Courtesy of FORD MOTOR CO.

Align the index-marks and position the universal joint flange on the drive pinion.
Using the special tool, install the axle universal joint flange.

Fig 17: Installing Axle Universal Joint Flange
Courtesy of FORD MOTOR CO.
Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.

Fig 18: Installing Pinion Nut
Courtesy of FORD MOTOR CO.

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.

Install the special tool, and tighten the pinion nut. Refer to Torque Specifications .
- 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 an Nm (inch/pound) torque wrench.
  
  Fig 19: Identifying Special Tool Installed To Tighten Pinion Nut
  Courtesy of FORD MOTOR CO.
  
  Fig 20: Checking Pinion Bearing Preload
  Courtesy of FORD MOTOR CO.

CAUTION: Use extreme care not to damage the aluminum differential carrier housing while performing the following procedure steps.

CAUTION: The special tools are marked LH and RH. Install them accordingly.

Fig 21: Installing Special Tools

Courtesy of FORD MOTOR CO.

Install the special tools.
Install the differential case with the Master Bearings in the differential carrier.

Fig 22: Installing Differential Case
Courtesy of FORD MOTOR CO.

NOTE: Repeat this step until you obtain a consistent reading.

Measure the total end play.
1. Position the special tools.
2. Position the indicator tip on the machined surface and adjust it to measure full travel.
3. Push the differential case left and right (as far as possible).
4. Measure the total end play and record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A, in this procedure.
  
  Fig 23: Measuring Total End Play
  Courtesy of FORD MOTOR CO.
Remove the special tools and the differential case.

Fig 24: Removing Special Tools & Differential Case
Courtesy of FORD MOTOR CO.
Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface.

Fig 25: Identifying Ring Gear Mounting Surface
Courtesy of FORD MOTOR CO.
Install the ring gear.
1. Position three bolts to align the holes in the ring gear and the differential case.
2. Using a suitable press, install the ring gear.
  
  Fig 26: Installing Ring Gear
  Courtesy of FORD MOTOR CO.
Install the remaining bolts.

Fig 27: Tightening Ring Gear Bolts
Courtesy of FORD MOTOR CO.
Remove three adjacent bolts.

Fig 28: Identifying Three Adjacent Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Position the three empty bolt holes downward.

Fig 29: Installing Differential Case Into Carrier Housing

Courtesy of FORD MOTOR CO.

Position the differential case with the special tools into the differential carrier housing.
Position the special tools.

Fig 30: Positioning Dial Indicator
Courtesy of FORD MOTOR CO.
Push and rock the ring gear into mesh with the pinion gear (zero backlash) and adjust the special tool to zero.

Fig 31: Pushing & Rocking Ring Gear Into Mesh With Pinion Gear
Courtesy of FORD MOTOR CO.
Move the ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line B, in this procedure.

Fig 32: Moving Ring Gear Away From Pinion Gear & Recording Reading
Courtesy of FORD MOTOR CO.
Remove the special tools.

Fig 33: Removing Special Tools
Courtesy of FORD MOTOR CO.
Remove the differential case and the special tools.

Fig 34: Removing Differential Case & Special Tools
Courtesy of FORD MOTOR CO.

NOTE: Measure both of the differential bearing stand heights prior to installing them on the differential case.

NOTE: Mark the left and right differential bearings before measuring them.

Fig 35: Clamping Special Tool Base In Vise

Courtesy of FORD MOTOR CO.

Clamp the special tool base in a soft jawed vise with the bearing mounting surface above the surface of the vise.
Position the differential bearing assembly in the special tool, and tighten the tool.

Fig 36: Positioning Differential Bearing Assembly In Special Tool
Courtesy of FORD MOTOR CO.
Measure the differential bearing stand height.
1. Invert the special tool and bearing assembly in the vise.
2. Use a depth micrometer to measure and record the differential bearing stand height.
  - Repeat the procedure for the other bearing.
    
    Fig 37: Measuring Differential Bearing Stand Height
    Courtesy of FORD MOTOR CO.
Select appropriate differential bearing shims.
Differential Bearing Shim Selection Chart

Fig 38: Differential Bearing Shim Selection Charts (1 Of 3)
Courtesy of FORD MOTOR CO.

Fig 39: Differential Bearing Shim Selection Charts (2 Of 3)
Courtesy of FORD MOTOR CO.

Fig 40: Differential Bearing Shim Selection Charts (3 Of 3)
Courtesy of FORD MOTOR CO.
Select the appropriate shim by the thickness or the stripe color.

Fig 41: Backlash Change & Shim Selection Chart
Courtesy of FORD MOTOR CO.

Fig 42: Identifying Shim
Courtesy of FORD MOTOR CO.

Differential Shim Size Chart

Fig 43: Differential Shim Size Chart
Courtesy of FORD MOTOR CO.
Install the three bolts.

Fig 44: Tightening Three Ring Gear Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Press against the bearing inner cone only.

Using a suitable press and the special tool, install the differential bearings.
1. Position the appropriate differential bearing (RH or LH).
2. Using a suitable press and the special tool, install the differential bearing.
  - Repeat the procedure for the other differential bearing.
    
    Fig 45: Installing Differential Bearings
    Courtesy of FORD MOTOR CO.

NOTE: Make sure the indicator needle is in the spreader adapter hole.

Fig 46: Installing Special Tool

Courtesy of FORD MOTOR CO.

Install the special tools.

CAUTION: Overspreading can damage the axle housing.

Spread the axle housing to the specification.
- Remove the Dial Indicator.
  
  Fig 47: Spreading Axle Housing To Specification
  Courtesy of FORD MOTOR CO.

CAUTION: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces can occur.

If removed, position the differential bearing shims.
1. Apply a light coating of Premium Long Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B to one side of the differential bearing shims to help hold them in place.
2. Position the differential bearing shims.
  
  Fig 48: Positioning Differential Bearing Shims
  Courtesy of FORD MOTOR CO.

NOTE: Push the differential case downward to fully seat the differential bearing cups in the axle housing.

Position the differential case assembly.
1. Position the differential bearing cups on the differential bearings.
2. Lower the differential case assembly in place between the differential bearing shims.
  
  Fig 49: Positioning Differential Case Assembly
  Courtesy of FORD MOTOR CO.
Install the bearing caps in their original positions and tighten with the housing still spread.
1. Position the bearing caps.
2. Install the bolts.
3. Remove the special tool.
  
  Fig 50: Installing Bearing Caps
  Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 51: Installing Special Tool
Courtesy of FORD MOTOR CO.
Measure the ring gear backlash at four places to obtain a consistent reading.
1. Mount the special tools on the indicator base.
2. Position the indicator needle and zero the indicator.
3. Turn the ring gear without turning the pinion gear and record the measurement.
  
  Fig 52: Measuring Ring Gear Backlash
  Courtesy of FORD MOTOR CO.

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 53: Increasing Backlash

Courtesy of FORD MOTOR CO.

To increase the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.

Fig 54: Decreasing Backlash
Courtesy of FORD MOTOR CO.
Liberally lubricate the axle shaft shift lever, and install a new O-ring.
- Use Ford Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or equivalent meeting Ford specification ESE-M1C171-A.
  
  Fig 55: Identifying Axle Shaft Shift Lever O-Rings
  Courtesy of FORD MOTOR CO.
Install the axle shaft shift lever.
1. Position the clutch fork.
2. Install the axle shaft shift lever.
  - Align the manual shaft retaining pin holes.
    
    Fig 56: Installing Axle Shaft Shift Lever
    Courtesy of FORD MOTOR CO.
Install the manual shaft retaining pin flush with the axle shaft shift lever.

Fig 57: Installing Manual Shaft Retaining Pin
Courtesy of FORD MOTOR CO.
Lift the axle shaft shift lever, and position the coupler shift selector gear, tapered end downward, into the clutch fork.

Fig 58: Installing Coupler Shift Selector Gear
Courtesy of FORD MOTOR CO.
Using the special tools, install the pilot bearing assembly into the axle cluster gear shaft.

Fig 59: Installing Pilot Bearing Assembly Into Axle Cluster Gear Shaft
Courtesy of FORD MOTOR CO.
Insert the axle cluster gear shaft through the coupler shift selector gear and engage the splines.

Fig 60: Inserting Axle Cluster Gear Shaft Through The Coupler Shift Selector Gear
Courtesy of FORD MOTOR CO.
Coat the thrust washer with grease, and position it on the axle cluster gear shaft.
- Use Premium Long Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
  
  Fig 61: Positioning Thrust Washer On Axle Cluster Gear Shaft
  Courtesy of FORD MOTOR CO.

CAUTION: Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber.

CAUTION: 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 has cured.

CAUTION: Do not allow any silicone rubber to squeeze inside during assembly.

Fig 62: Filling Groove With Silicone Gasket & Sealant

Courtesy of FORD MOTOR CO.

Fill the groove with Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.
Assemble the axle housing tube.
- Align the bolt holes and position the axle housing tube.
- Position the axle identification tag.
- Install the bolts.
  
  Fig 63: Assembling Axle Housing
  Courtesy of FORD MOTOR CO.
Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth.

Fig 64: Inspecting Axle Shaft Seal & Bearing Surface For Damage
Courtesy of FORD MOTOR CO.
Insert the axle shaft and engage it with the side gear.

Fig 65: Installing Axle Shaft
Courtesy of FORD MOTOR CO.

NOTE: Do not reuse the old snap ring.

Fig 66: Installing New Snap Ring

Courtesy of FORD MOTOR CO.

Push in on the axle shaft and install a new snap ring.
Install the clutch shaft rod boot.
1. Fully extend the actuator motor shaft and plug the vacuum ports.
2. Position the front axle actuator motor assembly.
3. Install the clutch shaft rod boot.
  
  Fig 67: Installing Clutch Shaft Rod Boot
  Courtesy of FORD MOTOR CO.
With the actuator motor shaft fully extended and the vacuum ports plugged, engage the shift lever.

Fig 68: Engaging Shift Lever
Courtesy of FORD MOTOR CO.
Seat the front axle actuator motor assembly and install the E-ring.

Fig 69: Seating Front Axle Actuator Motor Assembly & Installing E-Ring
Courtesy of FORD MOTOR CO.
Seat the clutch shaft rod boot in the slot in the actuator housing.
- Remove the plugs from the vacuum ports.
  
  Fig 70: Seating Clutch Shaft Rod Boot
  Courtesy of FORD MOTOR CO.

NOTE: Install a new vacuum motor if any vacuum leakage is observed.

NOTE: With the lever moved outboard, the axle is engaged and the axles will turn opposite of each other. With the lever moved inboard, the axle is disengaged and the axles will turn freely of each other.

Verify the front axle actuator motor assembly operation (engage).
- Using the special tool, apply vacuum to the outer vacuum port to move the shift lever outboard. Rotate one axle shaft to verify engagement.
  
  Fig 71: Verifying Front Axle Actuator Motor Assembly Engages
  Courtesy of FORD MOTOR CO.
Verify the front axle actuator motor assembly operation (disengage).
- Using the special tool, apply vacuum to the inner vacuum port to move the shift lever inboard. Rotate one axle to verify disengagement.
  
  Fig 72: Verifying Front Axle Actuator Motor Assembly Disengages
  Courtesy of FORD MOTOR CO.
Remove the axle assembly from the Holding Fixture and place it on the bench.

CAUTION: Remove all of the oil liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber.

CAUTION: 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 has cured.

Fig 73: Applying Sealant To Differential Housing Cover

Courtesy of FORD MOTOR CO.

Fill the sealing groove on the differential housing cover with Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.
Install the differential housing cover.
1. Position the differential housing cover.
2. Install the bolts.
  
  Fig 74: Installing Differential Housing Cover
  Courtesy of FORD MOTOR CO.
Fill the differential carrier housing, and install the fill plug.
- Use Motorcraft SAE75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A.
- Be sure to tighten both the drain and fill plugs.
  
  Fig 75: Identifying Fill Plug & Drain Plug
  Courtesy of FORD MOTOR CO.
Install the vacuum control shield.
- Install the shield.
- Install the bolts and the torque bolts.
Install the front drive axle assembly. Refer to the AXLE ASSEMBLY-Front Drive .