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Differential Ring and Pinion: 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
      G03199928Courtesy 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 Pinion Bearing Cups
    G03199929Courtesy 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
    G03199930Courtesy 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
      G03199931Courtesy 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
    G03199932Courtesy 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
    G03199933Courtesy 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
    G03199934Courtesy 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
    G03199935Courtesy 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: Pressing Differential Pinion Bearing Adjustment Shim And Inner Pinion Bearing On Differential Pinion Stem
    G03199936Courtesy 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
    G03199937Courtesy 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
    G03199938Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the new rear pinion oil seal.
  16. Using the special tools, install the rear axle pinion flange.
    Fig 12: Installing Rear Axle Pinion Flange
    G03199939Courtesy of FORD MOTOR CO.
    17. 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.
  17. 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
      G03199940Courtesy of FORD MOTOR CO.
  18. Tighten the differential drive pinion nut to set the differential pinion bearing preload.
    Fig 14: Tightening Differential Drive Pinion Nut
    G03199941Courtesy of FORD MOTOR CO.
  19. Install the special tools on the differential case.
    Fig 15: Installing Special Tools On Differential Case
    G03199942Courtesy of FORD MOTOR CO.
  20. Position the special tool on the differential case in the differential housing.
    Fig 16: Positioning Special Tool On Differential Case In Differential Housing
    G03199943Courtesy of FORD MOTOR CO.
  21. Install a unique set-up selective snap ring with a thickness of 2.54 mm (0.100 in).
    Fig 17: Installing Set-Up Selective Snap Ring With Thickness Of 2.54 mm (0.100 in)
    G03199944Courtesy of FORD MOTOR CO.
    22. NOTE: Repeat this step until obtaining a consistent reading.
  22. Measure the total end play.
    • Attach the special tools and position the indicator tip on the machined surface of the differential case flange.
    • Move the differential case to the left and the right (as far as possible).
    • Record the reading in Line A.
      DIFFERENTIAL BEARING SHIM SELECTION CHART

      8.0 Inch Lightweight Axle Example Actual
      Line A Total end play without ring gear 0.230 -
      Line B Total end play with ring gear 0.193 -
      Line C Subtract Line B from Line A 0.037 -
      Line D Initial backlash clearance 0.016 0.016
      Line E Set-up snap ring thickness 0.100 0.100
      Line F Left Master Bearing compensation 0.100 0.100
      Line G Carrier bearing preload 0.012 0.012

    To determine the snap ring thickness, add lines C, D and E (Example: 0.037 + 0.016 + 0.100 = 0.153 snap ring thickness).

    To determine the bearing shim thickness, add lines A, F and G. Subtract line C and D from the sum. Example:

    • 0.230 + 0.100 + 0.012 = 0.342
    • 0.342 - 0.037 - 0.016 = 0.289 bearing shim thickness
      • Fig 18: Measuring Total End Play
      G03199945Courtesy of FORD MOTOR CO.

  23. Remove the dial indicator and the differential case from the differential housing.
  24. Install the differential ring gear.
    1. Place the differential ring gear on the differential case.
    2. Hand start 3 differential ring gear bolts to align the holes in the differential ring gear and the differential case.
    3. Place the differential case and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
    4. Press the differential ring gear into place.
      5. Fig 19: Installing Differential Ring Gear
      G03199946Courtesy of FORD MOTOR CO.
  25. Install the remaining differential ring gear bolts. Apply sealer to the ring gear bolt threads.
    • Tighten to 120 N.m (89 lb-ft).
      • Fig 20: Tightening Differential Ring Gear Bolts
      G03199947Courtesy of FORD MOTOR CO.
  26. Place the differential case with the special tool into the differential housing.
    Fig 21: Placing Differential Case With Special Tool Into Differential Housing
    G03199948Courtesy of FORD MOTOR CO.
  27. Install the special tool.
    Fig 22: Installing Special Tool
    G03199949Courtesy of FORD MOTOR CO.
  28. Measure the end play.
    • Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
    • Rock the differential ring gear to allow full mesh with the drive pinion gear.
    • With the gears in full mesh, set the special tool to zero.
    • Move the differential case as far as possible to the left and note the reading.
    • Record the reading on the differential bearing shim selection procedure Line B.
      • Remove the special tool.
      • Fig 23: Measuring End Play
      G03199950Courtesy of FORD MOTOR CO.
  29. Remove the differential case from the differential housing.
    Fig 24: Removing Differential Case From Differential Housing
    G03199951Courtesy of FORD MOTOR CO.
  30. Using a suitable press, press the differential bearings on the differential case.
    Fig 25: Pressing Differential Bearings On Differential Case
    G03199952Courtesy of FORD MOTOR CO.
  31. Place the differential case and differential bearing cups in the differential case.
    Fig 26: Placing Differential Case And Differential Bearing Cups In Differential Case
    G03199953Courtesy of FORD MOTOR CO.
    32. NOTE: Select the correct size selective snap ring using the differential bearing shim selection chart.
    NOTE: To determine the thickness of the selective snap ring to be used, subtract Line B from Line A. Add Lines D and E to the difference. This is the thickness of the selective snap ring required.
    Fig 27: Placing Selective Snap Ring In Differential Housing
    G03199954Courtesy of FORD MOTOR CO.
  32. Place the selective snap ring in the differential housing.
    33. NOTE: Select the correct size selective bearing shim using the differential bearing shim selection chart.
    NOTE: To determine the thickness of the differential bearing shim to be used, add Lines A, F and G. Subtract Lines C and D from the sum. This is the thickness of the differential bearing shim required.
    Fig 28: Positioning Differential Bearing Shim
    G03199955Courtesy of FORD MOTOR CO.
  33. Position the differential bearing shim indicated by the differential bearing shim selection chart.
  34. Using the special tools, seat the differential bearing shim in the differential housing.
    Fig 29: Seating Differential Bearing Shim In Differential Housing
    G03199956Courtesy of FORD MOTOR CO.
  35. Install the differential bearing cap, then the differential bearing cap bolts in the original location.
    • Tighten to 105 N.m (77 lb-ft).
    Fig 30: Tightening Differential Bearing Cap Bolts
    G03199957Courtesy of FORD MOTOR CO.
  36. Lubricate the lips of the halfshaft housing seal with grease.
  37. 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 31: Measuring Differential Ring Gear Backlash
      G03199958Courtesy of FORD MOTOR CO.
  38. 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 4.21 0.1657
    5 PINK/1 BLK 4.23 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 6.1722- 6.1849 0.2430- 0.2435
    1 - RED 6.1214- 6.1341 0.2410- 0.2415
  39. Using the special tools, install the halfshaft housing seal.
    Fig 32: Installing Halfshaft Housing Seal
    G03199959Courtesy of FORD MOTOR CO.
  40. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  41. Verify an acceptable pattern check. For additional information, refer to DIAGNOSIS AND TESTING .
  42. Remove the differential assembly from the special tool.
    Fig 33: Removing Differential Assembly From Special Tool
    G03199960Courtesy of FORD MOTOR CO.
    43. CAUTION: The differential housing cover must be installed within 15 minutes of application of the sealant.
    CAUTION: Allow the Silicone Gasket and Sealant to cure for 1 hour before filling the axle with lubricant.
  43. Apply a continuous bead of Silicone Gasket and Sealant to the differential housing cover mounting surface, then install the differential housing cover.
  44. Install the rear axle assembly. For additional information, refer to REAR AXLE ASSEMBLY .
  45. Fill the axle with the specified amount of specified lubricant.
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