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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 383 (Rear Drive Axle/Differential 7.5-Inch Ring Gear) >> In-Vehicle Repair >> Differential Bearings >> Installation

Differential Bearings: Installation

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the special tool and the inner and outer drive pinion bearing cups in their respective bores.
    1. After placing the inner and outer drive pinion bearing cups in their bores, place the special tool (inner) on the inner drive pinion bearing cup.
    2. Place the special tool (outer) on the outer drive pinion bearing cup.
    3. Install the special tool.
    Fig 1: Installing Special Tool
    G03434338Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the drive pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool To Seat Drive Pinion Bearing Cups
    G03434339Courtesy of FORD MOTOR CO.
    3. NOTE: If a feeler gauge can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly seated.
    Fig 3: Inserting Feeler Gauge Between Drive Pinion Bearing Cup & Bottom Of Bore
    G03434340Courtesy of FORD MOTOR CO.
    Fig 4: Assembling Drive Pinion Bearings & Special Tool
    G03434341Courtesy of FORD MOTOR CO.
  3. Make sure the drive pinion bearing cups are correctly seated in their bores.
    4. NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.
    Fig 5: Positioning Special Tools
    G03434342Courtesy of FORD MOTOR CO.
  4. Assemble and position the special tools.
    5. NOTE: This step duplicates final drive pinion bearing preload.
    Fig 6: Tightening Special Tool
    G03434343Courtesy of FORD MOTOR CO.
  5. Tighten the special tool.
    • Tighten to 2.2 Nm (20 lb-in).
    6. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 7: Offsetting Special Tool
    G03434344Courtesy of FORD MOTOR CO.
  6. Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings and position the special tool.
  7. Install the special tool.
    1. Position the special tool.
    2. Install the differential bearing caps.
    3. Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    Fig 8: Installing Special Tool
    G03434345Courtesy of FORD MOTOR CO.
    8. NOTE: Drive pinion bearing adjustment shims must be flat and clean.
    NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.
    Fig 9: Using Drive Pinion Bearing Adjustment Shim As A Gauge
    G03434346Courtesy of FORD MOTOR CO.
  8. Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
    • After the correct drive pinion bearing adjustment shim thickness has been determined, remove all of the special tools.
  9. Using the special tool, press the inner drive pinion bearing and drive pinion bearing adjustment shim until it is firmly seated on the pinion shaft.
    Fig 10: Installing Inner Drive Pinion Bearing & Adjustment
    G03434347Courtesy of FORD MOTOR CO.
  10. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
    Fig 11: Installing Drive Pinion Collapsible Spacer
    G03434348Courtesy of FORD MOTOR CO.
  11. Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
    Fig 12: Installing Outer Drive Pinion Bearing & Drive Pinion Shaft Oil Slinger
    G03434349Courtesy of FORD MOTOR CO.
  12. Using the special tools, install the drive pinion seal.
    Fig 13: Installing Drive Pinion Seal
    G03434350Courtesy of FORD MOTOR CO.
  13. Install the drive pinion assembly into the axle housing.
    Fig 14: Installing Drive Pinion Assembly Into Axle Housing
    G03434351Courtesy of FORD MOTOR CO.
  14. Using the special tools, install the drive pinion flange.
    Fig 15: Installing Drive Pinion Flange
    G03434352Courtesy of FORD MOTOR CO.
    15. CAUTION: Do not, under any circumstance, loosen the drive pinion nut to reduce pinion bearing preload. If it is necessary to reduce the preload, install a new drive pinion collapsible spacer and drive pinion nut.
    CAUTION: Remove the special tool while taking rotational pinion bearing preload checks with the Nm (inch-pound) torque wrench.
    Fig 16: Tightening Pinion Nut
    G03434353Courtesy of FORD MOTOR CO.
  15. Use the special tool to hold the pinion flange while tightening the pinion nut.
    • Rotate the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload checks by rotating the differential pinion with a Nm (inch-pound) torque wrench. Tighten the pinion nut in small increments to avoid excessive pinion bearing preload. Tighten the pinion nut until the drive pinion bearing preload is in specification.
      • Tighten to a rotational torque of 1.8-31.3 Nm (16-219 lb-in).
  16. Using the special tool, install the new differential bearings.
    Fig 17: Installing Differential Bearings
    G03434354Courtesy of FORD MOTOR CO.
  17. Position the differential carrier assembly and the new differential bearing cups in the differential housing.
    Fig 18: Installing Differential Carrier Assembly & Differential Bearing Cups
    G03434355Courtesy of FORD MOTOR CO.
  18. Install a differential bearing shim of the shown dimension on the left side.
    Fig 19: Installing LH Differential Bearing Shim
    G03434356Courtesy of FORD MOTOR CO.
    19. CAUTION: Always install the bearing caps in their original locations and positions.
    NOTE: Apply pressure toward the LH side to make sure the left differential bearing cup seats correctly.
    Fig 20: Installing LH Bearing Cap & Bolts
    G03434357Courtesy of FORD MOTOR CO.
  19. Install the LH bearing cap and loosely install the bolts.
  20. Install progressively larger differential bearing shims on the RH side until the largest shim is installed by hand.
    Fig 21: Installing Progressively Larger RH Differential Bearing Shims
    G03434358Courtesy of FORD MOTOR CO.
  21. Install the RH side bearing cap and bolts. Tighten the left and right bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
  22. Rotate the differential carrier several times to verify the differential bearings have seated correctly.
    Fig 22: Rotating Differential Carrier
    G03434359Courtesy of FORD MOTOR CO.
  23. Install the special tools and measure the ring gear backlash.
    • If the backlash is within specification, proceed to step  26 .
    • If a zero backlash condition occurs, proceed to step  24 .
    • If the backlash is not within specification, proceed to step  25 .
    Fig 23: Measuring Ring Gear Backlash
    G03434360Courtesy of FORD MOTOR CO.
  24. If a zero backlash condition occurs, add 0.50 mm (0.020 in) to the RH side shim and subtract 0.50 mm (0.020 in) from the LH side shim to allow a backlash indication. Go back to Step  23 .
  25. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to BACKLASH SPECIFICATIONS  table when adjusting the backlash. When the backlash is within specification, proceed to step  26 .
    BACKLASH SPECIFICATIONS

    Backlash Change Required Thickness Change Required
    mm in mm in
    0.025 0.001 0.050 0.002
    0.050 0.002 0.050 0.002
    0.076 0.003 0.101 0.004
    0.101 0.004 0.152 0.006
    0.127 0.005 0.152 0.006
    0.152 0.006 0.203 0.008
    0.177 0.007 0.254 0.010
    0.203 0.008 0.254 0.010
    0.228 0.009 0.304 0.012
    0.254 0.010 0.355 0.014
    0.279 0.011 0.355 0.014
    0.304 0.012 0.406 0.016
    0.330 0.013 0.457 0.018
    0.335 0.014 0.457 0.018
    0.381 0.015 0.508 0.020
    DIFFERENTIAL SHIM SIZE CHART 4067

    Stripes & Color Code Dimension A
    mm in
    2 - C-COAL 7.7978-7.8105 0.3070-01.3075
    1 - C-COAL 7.7470-7.7597 0.3050-01.3055
    5 - BLU 7.6962-7.7089 0.3030-01.3035
    4 - BLU 7.6454-7.6581 0.3010-01.3015
    3 - BLU 7.5946-7.6073 0.2990-01.2995
    2 - BLU 7.5458-7.5565 0.2970-01.2975
    5 - PINK 7.4422-7.4549 0.2930-01.2935
    4 - PINK 7.3914-7.4041 0.2910-01.2915
    3 - PINK 7.3406-7.3533 0.2890-01.2895
    2 - PINK 7.2898-7.3025 0.2870-01.2875
    1 - PINK 7.2390-7.2517 0.2850-01.2855
    5 - GRN 7.1882-7.2009 0.2830-01.2835
    4 - GRN 7.1374-7.1501 0.2810-01.2815
    3 - GRN 7.0866-7.0993 0.2790-01.2795
    2 - GRN 7.0358-7.0485 0.2770-01.2775
    1 - GRN 6.9850-7.0485 0.2750-01.2755
    5 - WH 6.9342-6.9469 0.2730-01.2735
    4 - WH 6.8834-6.8961 0.2710-01.2715
    3 - WH 6.8326-6.8453 0.2690-01.2695
    2 - WH 6.7818-6.7945 0.2670-0.2675
    1 - WH 6.7310-6.7437 0.2650-0.2655
    5 - YEL 6.6802-6.6929 0.2630-0.2635
    4 - YEL 6.6294-6.6421 0.2610-0.2615
    3 - YEL 6.5786-6.5913 0.2590-0.2595
    2 - YEL 6.5278-6.5405 0.2570-0.2575
    1 - YEL 6.4770-6.4897 0.2550-0.2555
    5 - ORNG 6.4262-6.4389 0.2530-0.2535
    4 - ORNG 6.3754-6.3881 0.2510-0.2515
    3 - ORNG 6.3246-6.3373 0.2490-0.2495
    2 - ORNG 6.2738-6.2865 0.2470-0.2475
    1 - ORNG 6.2223-6.2357 0.2450-0.2455
    2 - RED 6.1722-6.1849 0.2430-0.2435
    1 - RED 6.1214-6.1341 0.2410-0.2415
  26. Remove the bearing cap bolts and bearing caps.
  27. To establish differential bearing preload, increase both LH and RH differential bearing shim size by the thickness shown.
    Fig 24: Increasing Differential Bearing Shim Sizes
    G03434361Courtesy of FORD MOTOR CO.
  28. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 25: Fully Seating Differential Bearing Shims
    G03434362Courtesy of FORD MOTOR CO.
  29. Install the bearing caps and bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 26: Installing Bearing Caps & Bolts
    G03434363Courtesy of FORD MOTOR CO.
  30. Using the special tools, recheck the ring gear backlash.
  31. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  32. Verify an acceptable pattern check.
  33. Install the axle shafts. For additional information, refer to AXLE SHAFT  .
  34. Position the driveshaft and align the index marks on the pinion flange.
    Fig 27: Installing Driveshaft Aligning Index Marks On Pinion Flange
    G03434364Courtesy of FORD MOTOR CO.
    35. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.
    Fig 28: Installing Driveshaft Flange Bolts
    G03434365Courtesy of FORD MOTOR CO.
  35. Install the driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
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