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Differential Bearings: Assembly

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using the special tool, install the differential drive pinion bearing cups.
    • Position the bearing cups on the special tool.
    • Position the special tool and the bearing cups in the differential housing.
    • Tighten the special tool to fully seat the bearing cups in the bores.
      • Fig 1: Installing Differential Drive Pinion Bearing Cups
      G03199977Courtesy of FORD MOTOR CO.
    2. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.
    Fig 2: Checking Seating Of Differential Drive Pinion Bearing Cups
    G03199978Courtesy of FORD MOTOR CO.
  2. Make sure the differential pinion bearing cups are correctly seated.
    3. CAUTION: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.
    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 3: Installing Differential Pinion Bearings And Special Tools
    G03199979Courtesy of FORD MOTOR CO.
  3. Install the differential pinion bearings and special tools as shown.
    4. NOTE: This step duplicates differential pinion bearing preload.
  4. Thread the special tool onto the screw.
    • Tighten to 2.2 N.m (20 lb-in).
      • Fig 4: Threading Special Tool Onto Screw
      G03199980Courtesy of FORD MOTOR CO.
    5. CAUTION: Offset the special tool to obtain an accurate reading.
    Fig 5: Rotating Special Tool Several Half Turns To Seat Differential Pinion Bearings
    G03199981Courtesy of FORD MOTOR CO.
  5. Rotate the special tool several half turns to seat the differential pinion bearings. Position the special tool as shown.
  6. Install the special tool.
    • Position the special tool in the differential housing differential bearing seat.
      • Fig 6: Positioning Special Tool In Differential Housing Differential Bearing Seat
      G03199982Courtesy of FORD MOTOR CO.
  7. Install the differential bearing cap, then install the differential bearing cap bolts.
    • Tighten to 105 N.m (77 lb-ft).
      • Fig 7: Tightening Differential Bearing Cap Bolts
      G03199983Courtesy of FORD MOTOR CO.
  8. Use a differential pinion bearing adjustment shim as a gauge for shim selection. Check the differential pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. A slight drag indicates correct differential pinion bearing adjustment shim selection.
    Fig 8: Checking Differential Pinion Bearing Adjustment Shim Thickness Between Gauge Block And Gauge Tube
    G03199984Courtesy of FORD MOTOR CO.
  9. Remove all of the special tools.
    10. CAUTION: Use the same differential pinion bearings and differential pinion bearing adjustment shim from the differential pinion bearing adjustment shim selection procedure for final assembly.
  10. Position the differential pinion bearing adjustment shim and the inner pinion bearing on the differential pinion stem.
  11. Using the special tools and a suitable press, firmly seat the differential pinion bearing adjustment shim and inner pinion bearing on the differential pinion stem.
    Fig 9: Installing Differential Pinion Bearing Adjustment Shim And Inner Pinion Bearing
    G03199985Courtesy of FORD MOTOR CO.
    12. CAUTION: Make sure the splines on the differential pinion stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth.
    Fig 10: Placing Drive Pinion Collapsible Spacer On Differential Pinion Stem
    G03199986Courtesy of FORD MOTOR CO.
  12. Place a new drive pinion collapsible spacer on the differential pinion stem against the differential pinion stem shoulder.
  13. Install the differential pinion gear with the drive pinion collapsible spacer in the differential housing.
  14. Install the outer pinion bearing and rear pinion oil seal slinger.
    15. CAUTION: Installation without the correct tool can result in early rear pinion oil seal failure.
    CAUTION: If the rear pinion oil seal becomes misaligned during installation, remove it and install a new one.
    NOTE: Coat the rear pinion oil seal lips with grease.
    Fig 11: Installing Rear Pinion Oil Seal
    G03199987Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the new rear pinion oil seal.
    16. NOTE: Disregard the index marks if installing a new rear axle pinion flange.
  16. Position the rear axle pinion flange.
    • Lubricate the rear axle pinion flange splines with grease.
  17. Using the special tools, install the rear axle pinion flange.
    Fig 12: Installing Rear Axle Pinion Flange
    G03199988Courtesy of FORD MOTOR CO.
    18. CAUTION: Do not, under any circumstance, loosen the differential drive pinion nut to reduce differential pinion bearing preload. If it is necessary to reduce differential pinion bearing preload, install a new drive pinion collapsible spacer and differential drive pinion nut.
    CAUTION: Remove the special tool while taking differential pinion bearing preload readings with the N.m (lb-in) torque wrench.
  18. Use the special tool to hold the rear axle pinion flange while tightening the differential drive pinion nut.
    • Rotate the differential pinion gear occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the differential pinion gear with a N.m (lb-in) torque wrench.
      • Fig 13: Rotating Differential Pinion Gear With N.m (lb-in) Torque Wrench
      G03199989Courtesy of FORD MOTOR CO.
  19. Tighten the differential drive pinion nut to set the differential pinion bearing preload.
    Fig 14: Tightening Differential Drive Pinion Nut
    G03199990Courtesy of FORD MOTOR CO.
  20. Using a suitable press, press the differential bearings on the differential case.
    Fig 15: Pressing Differential Bearings On Differential Case
    G03199991Courtesy of FORD MOTOR CO.
  21. Place the differential case and differential bearing cups in the differential case.
    Fig 16: Placing Differential Case And Differential Bearing Cups In Differential Case
    G03199992Courtesy of FORD MOTOR CO.
  22. Place the original selective snap ring in the differential housing.
    Fig 17: Placing Original Selective Snap Ring In Differential Housing
    G03199993Courtesy of FORD MOTOR CO.
  23. Position the original differential bearing shim.
    Fig 18: Positioning Original Differential Bearing Shim
    G03199994Courtesy of FORD MOTOR CO.
  24. Using the special tools, seat the differential bearing shim in the differential housing.
    Fig 19: Installing Differential Bearing Shim In Differential Housing
    G03199995Courtesy of FORD MOTOR CO.
  25. Install the differential bearing cap, then the differential bearing cap bolts in their original locations.
    • Tighten to 105 N.m (77 lb-ft).
      • Fig 20: Installing Differential Bearing Cap
      G03199996Courtesy of FORD MOTOR CO.
  26. Lubricate the lips of the halfshaft housing seal.
    • Use Premium Long-Life Grease XG-1-C meeting Ford specification ESA-M1C75-B.
  27. Using the special tools, install the halfshaft housing seal.
    Fig 21: Installing Halfshaft Housing Seal
    G03199997Courtesy of FORD MOTOR CO.
  28. Using the special tools, measure the differential ring gear backlash at 4 equally spaced points.
    • Attach the special tool.
    • Position the special tool tip centrally on a drive tooth.
    • Zero the indicator.
    • Turn the differential ring gear without turning the differential pinion gear. Record the indicator reading. The allowable backlash is 0.127 mm (0.005 in) to 0.228 mm (0.009 in) and must not vary more than 0.076 mm (0.003 in) between points measured. A backlash variation of more than 0.076 mm (0.003 in) between points checked indicates gear/case runout.
      • If backlash is within specifications, install the axle assembly.
      • To correct for a high or low backlash, proceed as follows.
      • Fig 22: Measuring Differential Ring Gear Backlash
      G03199998Courtesy of FORD MOTOR CO.
  29. To correct for high or low backlash, increase or decrease the thickness of the differential bearing shim and decrease or increase the thickness of the selective snap ring by the same amount. Refer to the following tables when adjusting the backlash. When the backlash is within specifications, install the differential assembly.
    BACKLASH CHANGE REQUIRED AND THICKNESS CHANGE REQUIRED

    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
    0.381    		 0.014
    0.015    		 0.457
    0.508    		 0.018
    0.020

    Differential Snap Ring Size Chart - 13277 

    DIFFERENTIAL SNAP RING SIZE CHART - 13277

    Numbers of Stripes and Color Code Dimension A
    mm in
    1 YEL 3.15 0.1240
    2 YEL 3.17 0.1248
    3 YEL 3.19 0.1256
    4 YEL 3.21 0.1264
    5 YEL 3.23 0.1272
    1 WH 3.25 0.1280
    2 WH 3.27 0.1287
    3 WH 3.29 0.1295
    4 WH 3.31 0.1303
    5 WH 3.33 0.1311
    1 GRN 3.35 0.1319
    2 GRN 3.37 0.1327
    3 GRN 3.39 0.1335
    4 GRN 3.41 0.1343
    5 GRN 3.43 0.1350
    1 PINK 3.45 0.1358
    2 PINK 3.47 0.1366
    3 PINK 3.49 0.1374
    4 PINK 3.51 0.1382
    5 PINK 3.53 0.1390
    1 BLU 3.55 0.1398
    2 BLU 3.57 0.1406
    3 BLU 3.59 0.1413
    4 BLU 3.61 0.1421
    5 BLU 3.63 0.1429
    1 BLK 3.65 0.1437
    2 BLK 3.67 0.1445
    3 BLK 3.69 0.1453
    4 BLK 3.71 0.1461
    5 BLK 3.73 0.1469
    1 BROWN 3.75 0.1476
    2 BROWN 3.77 0.1484
    3 BROWN 3.79 0.1492
    4 BROWN 3.81 0.1500
    5 BROWN 3.83 0.1508
    1 YEL/1 BLK 3.85 0.1516
    2 YEL/1 BLK 3.87 0.1524
    3 YEL/1 BLK 3.89 0.1531
    4 YEL/1 BLK 3.91 0.1539
    5 YEL/1 BLK 3.93 0.1547
    1 WH/1 BLK 3.95 0.1555
    2 WH/1 BLK 3.97 0.1563
    3 WH/1 BLK 3.99 0.1571
    4 WH/1 BLK 4.01 0.1579
    5 WH/1 BLK 4.03 0.1587
    1 GRN/1 BLK 4.05 0.1594
    2 GRN/1 BLK 4.07 0.1602
    3 GRN/1 BLK 4.09 0.1610
    4 GRN/1 BLK 4.11 0.1618
    5 GRN/1 BLK 4.13 0.1626
    1 PINK/1 BLK 4.15 0.1634
    2 PINK/1 BLK 4.17 0.1642
    3 PINK/1 BLK 4.19 0.1650
    4 PINK/1 BLK 5 PINK/1 BLK 4.21 4.23 0.1657 0.1665

    Differential Shim Size Chart - 4067 

    DIFFERENTIAL SHIM SIZE CHART - 4067

    Numbers of Stripes and Color Code Dimension A
    mm in
    2 - C-COAL 7.7978- 7.8105 0.3070- 0.3075
    1 - C-COAL 7.7470- 7.7597 0.3050- 0.3055
    5 - BLU 7.6962- 7.7089 0.3030- 0.3035
    4 - BLU 7.6454- 7.6581 0.3010- 0.3015
    3 - BLU 7.5946- 7.6073 0.2990- 0.2995
    2 - BLU 7.5458- 7.5565 0.2970- 0.2975
    1 - BLU 7.493- 7.505 0.2950- 0.2955
    5 - PINK 7.4422- 7.4549 0.2930- 0.2935
    4 - PINK 7.3914- 7.4041 0.2910- 0.2915
    3 - PINK 7.3406- 7.3533 0.2890- 0.2895
    2 - PINK 7.2898- 7.3025 0.2870- 0.2875
    1 - PINK 7.2390- 7.2517 0.2850- 0.2855
    5 - GRN 7.1882- 7.2009 0.2830- 0.2835
    4 - GRN 7.1374- 7.1501 0.2810- 0.2815
    3 - GRN 7.0866- 7.0993 0.2790- 0.2795
    2 - GRN 7.0358- 7.0485 0.2770- 0.2775
    1 - GRN 6.9850- 7.0485 0.2750- 0.2755
    5 - WH 6.9342- 6.9469 0.2730- 0.2735
    4 - WH 6.8834- 6.8961 0.2710- 0.2715
    3 - WH 6.8326- 6.8453 0.2690- 0.2695
    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
    1 - RED    		 6.1722- 6.1849
    6.1214- 6.1341    		 0.2430- 0.2435
    0.2410- 0.2415
  30. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  31. Verify an acceptable pattern check. For additional information, refer to NOISE, VIBRATION & HARSHNESS .
  32. Remove the differential assembly from the special tool.
    Fig 23: Removing Differential Assembly From Special Tool
    G03199999Courtesy of FORD MOTOR CO.
    33. CAUTION: The differential housing cover must be installed within 15 minutes of application of the Silicone Gasket and Sealant F7AZ-19554-EA meeting Ford specification WSE-M4G323-A4.
    CAUTION: Allow the Silicone Gasket and Sealant to cure for 1 hour before filling the axle with lubricant.
  33. Apply a continuous bead of Silicone Gasket and Sealant to the differential housing cover mounting surface, then install the differential housing cover.
  34. Fill the axle with the specified amount of the specified lubricant.
  35. Install the rear axle assembly. For additional information, refer to AXLE ASSEMBLY .
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