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Differential Bearings: Installation

WARNING: This page is about a different car, the 2004 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 rear axle lubricant. Also, lubricate the subassembly when installing it into the differential housing. Tighten all fasteners to specification.
  1. Lubricate the new differential drive pinion bearing cups.
  2. Using the special tools, install the differential drive pinion bearing cups.
    Fig 1: Installing Differential Drive Pinion Bearing Cups
    G03272938Courtesy 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 And Positioning Differential Housing Components
      G03272939Courtesy of FORD MOTOR CO.
  4. Using a N.m (pound-inch) torque wrench, tighten the Handle.
    Fig 3: Tightening Handle Of Special Tool
    G03272940Courtesy of FORD MOTOR CO.
    5. NOTE: Offset the Gauge Block to obtain an accurate reading.
    Fig 4: Positioning Gauge Block
    G03272941Courtesy 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.
      • Tighten to 61 N.m (45 lb-ft).
        Fig 5: Installing Special Tool And Paper Shipping Tags
        G03272942Courtesy 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: Measuring Thickness Between Gauge Block And Gauge Tube
      G03272943Courtesy 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.
    • Notice the plus (+), minus (-), or zero (0) etching on the drive pinion, and adjust the thickness of the new shim. If the etching is positive, subtract the number from the selected position shim. If the etching is negative, subtract the number from the selected position shim.
    • The selected shim thickness should be very close to the recorded thickness of the original position shim.
      Fig 7: Locating Etching On Drive Pinion
      G03272944Courtesy of FORD MOTOR CO.
  9. 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 And Differential Pinion Bearing
      G03272945Courtesy of FORD MOTOR CO.
  10. Install a new collapsible spacer.
    Fig 9: Installing Collapsible Spacer
    G03272946Courtesy of FORD MOTOR CO.
  11. Install the differential pinion bearing and the front axle drive pinion shaft oil slinger.
    Fig 10: Installing Differential Pinion Bearing And Front Axle Drive Pinion Shaft Oil Slinger
    G03272947Courtesy of FORD MOTOR CO.
    12. 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.
    NOTE: Pinion seal must be fully seated all the way around or pinion seal damage will occur.
    Fig 11: Installing Pinion Seal
    G03272948Courtesy of FORD MOTOR CO.
  12. Using the special tool, install the pinion seal.
  13. Lightly lubricate the pinion gear splines.
  14. Position the pinion gear in the axle housing.
    Fig 12: Positioning Pinion Gear In Axle Housing
    G03272949Courtesy of FORD MOTOR CO.
    15. 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: Aligning/ Installing Pinion Flange
    G03272950Courtesy of FORD MOTOR CO.
  15. Align the index marks and install the pinion flange.
  16. Install the new nut hand-tight.
    Fig 14: Installing Pinion Flange Nut Hand-Tight
    G03272951Courtesy of FORD MOTOR CO.
    17. CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.
    NOTE: Remove the special tool before taking the differential pinion bearing preload reading.
  17. Use the special tool to hold the pinion flange while tightening the nut to set the preload.
    • Rotate the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a N.m (inch-pound) torque wrench. The final rotational reading must be 1.7-3.4 N.m (15-30 lb-in).
      Fig 15: Holding Pinion Flange
      G03272952Courtesy of FORD MOTOR CO.
  18. Install the special tool.
    Fig 16: Installing Special Tool
    G03272953Courtesy of FORD MOTOR CO.
  19. Install the differential case in the differential housing.
    Fig 17: Installing Differential Case In Differential Housing
    G03272954Courtesy of FORD MOTOR CO.
    20. NOTE: Repeat this step until obtaining a consistent reading.
  20. 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.
      Fig 18: Measuring Total End Play
      G03272955Courtesy of FORD MOTOR CO.
  21. Remove the special tool, and remove the differential case.
    1. Remove the special tool.
    2. Remove the differential case.
      Fig 19: Removing Special Tool And Differential Case
      G03272956Courtesy of FORD MOTOR CO.
    22. CAUTION: Do not reuse the original bolts.
  22. Using a suitable press, install the differential ring gear.
    1. Position the differential ring gear and the differential case. Start 2 or 3 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 20: Installing Differential Ring Gear
      G03272957Courtesy of FORD MOTOR CO.
  23. Install the remaining new differential ring gear bolts.
    • Tighten to 122 N.m (90 lb-ft).
      Fig 21: Installing Differential Ring Gear Bolts
      G03272958Courtesy of FORD MOTOR CO.
  24. 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 22: Installing Special Tool And Positioning Assembly In Differential Housing
      G03272959Courtesy of FORD MOTOR CO.
  25. Position the special tool.
    Fig 23: Positioning Special Tool
    G03272960Courtesy of FORD MOTOR CO.
  26. Force the differential ring gear into mesh with the pinion gear (zero backlash). With force still applied, set the special tool to zero.
    Fig 24: Zeroing Dial Indicator
    G03272961Courtesy of FORD MOTOR CO.
  27. 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.
    Fig 25: Measuring Differential Movement
    G03272962Courtesy of FORD MOTOR CO.
  28. Remove the special tool.
    Fig 26: Removing Special Tool
    G03272963Courtesy of FORD MOTOR CO.
  29. Remove the differential case from the differential housing. Remove the special tool from the differential case hubs.
    Fig 27: Removing Special Tool From Differential Case Hubs
    G03272964Courtesy of FORD MOTOR CO.
  30. 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), 0.25 mm (0.010 in) and 0.762 mm (0.030 in) thickness.
    DIFFERENTIAL BEARING SHIM SELECTION PROCEDURE WORKSHEET

    Line Item Result (actual) Result (example)
    A Total end play reading (without gears)   2.032 mm (0.080 in)
    B Add preload +0.2032 mm (+0.008 in) +0.2032 mm (+0.008 in)
    C Total (add A and B)   2.2352 mm (0.088 in)
    D End play measurement (with gears)   1.0414 mm (0.041 in)
    E Subtract the shim thickness on the ring gear side -0.0762 mm (-0.003 in) -0.0762 mm (-0.003 in)
    F Total (subtract E from D) (thickness of shims to place on the ring gear side)   0.9652 mm (0.038 in)
    G Total (subtract F from C) (thickness of shims to place on the drive pinion side)   1.27 mm (0.050 in)
  31. 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 28: Installing Differential Shims And Bearing
        G03272965Courtesy of FORD MOTOR CO.
  32. Install the special tools.
    • Position the Clutch Housing Alignment Adapter needle in the Housing Spreader Adapter hole.
      Fig 29: Installing Clutch Housing Alignment Adapter Needle In Housing Spreader Adapter Hole
      G03272966Courtesy of FORD MOTOR CO.
    33. CAUTION: Over spreading can damage the differential housing.
    Fig 30: Spreading Differential Housing
    G03272967Courtesy of FORD MOTOR CO.
  33. Spread the differential housing to the specification.
  34. Remove the special tools.
    Fig 31: Removing Special Tools
    G03272968Courtesy of FORD MOTOR CO.
    35. NOTE: Push the differential case downward to fully seat the differential bearing cups in the differential housing.
  35. 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 32: Installing Differential Bearing Cups And Differential Case In Differential Housing
      G03272969Courtesy of FORD MOTOR CO.
    36. CAUTION: Do not tighten the bolts to specification at this time.
  36. Install the differential bearing caps in their original positions.
    1. Position the differential bearing caps.
    2. Install the bolts hand-tight.
      Fig 33: Installing Differential Bearing Caps
      G03272970Courtesy of FORD MOTOR CO.
  37. Remove the special tools.
  38. Tighten the bolts.
    • Tighten to 61 N.m (45 lb-ft).
      Fig 34: Tightening Bearing Cap Bolt
      G03272971Courtesy of FORD MOTOR CO.
  39. Verify that the differential case rotates freely.
  40. Using the special tools, measure the backlash at 3 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.
      • 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 35: Measuring Differential Ring Gear Backlash
        G03272972Courtesy of FORD MOTOR CO.
  41. Remove the special tools.
    Fig 36: Removing Special Tools
    G03272973Courtesy of FORD MOTOR CO.
  42. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  43. Verify an acceptable pattern check. For additional information, refer to DIAGNOSIS AND TESTING .
  44. Install the RH axle shaft.
    45. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.
    CAUTION: Install the differential housing cover within 15 minutes of applying the silicone material.
    CAUTION: Allow the sealant to cure for 1 hour before filling the axle with lubricant.
    Fig 37: Applying Sealant To Differential Housing Cover Mounting Surface
    G03272974Courtesy of FORD MOTOR CO.
  45. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
  46. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 29 N.m (21 lb-ft).
  47. Install the axle assembly. For additional information, refer to AXLE ASSEMBLY - FRONT .
  48. Fill the axle with 1.54 liters (3.25 pints) of lubricant.
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