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Differential Ring and Pinion - Rear Axle: Installation

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. 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.
    1. Position the bearing cups on the special tool.
    2. Position the special tool and the differential drive pinion bearing cups in the differential housing.
    3. Tighten the special tool to fully seat the differential drive pinion bearing cups in the bores.
    Fig 1: Installing Differential Drive Pinion Bearing Cups
    G03190210Courtesy 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: Measuring Feeler Gauge Between Cup And Bottom
    G03190211Courtesy 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 Drive Pinion Bearings Using Special Tools
    G03190212Courtesy of FORD MOTOR CO.
  3. Install the new drive pinion bearings and special tools as shown.
    4. NOTE: This step duplicates drive pinion bearing preload.
    Fig 4: Tightening Nut
    G03190213Courtesy of FORD MOTOR CO.
  4. Thread the special tool onto the screw and tighten to the specification.
    • Tighten to 2.2 Nm (20 lb-in).
    5. CAUTION: Position the adapter so it does not contact the housing.
    CAUTION: Offset the special tool to obtain an accurate reading.
    Fig 5: Rotating Special Tool To Seat Drive Pinion Bearings
    G03190214Courtesy of FORD MOTOR CO.
  5. Rotate the special tool several half turns to seat the drive pinion bearings. Position the special tool as shown.
  6. Install the special tool.
    1. Position the special tool on the differential housing differential bearing seat.
    2. Install the differential bearing caps.
    3. Install the differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    Fig 6: Installing Special Tool And Differential Bearing Caps
    G03190215Courtesy of FORD MOTOR CO.
  7. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the gauge block and the gauge tube. A slight drag indicates correct shim selection.
    • Notice the plus (+), minus (-) or zero (0) paint marking on the drive pinion stem and adjust the thickness of the new shim. If the marking is plus (+), subtract the number from the gauged shim thickness. If the marking is minus (-), add the number to the gauged shim thickness.
    Fig 7: Checking Drive Pinion Bearing Adjustment Shim Selection
    G03190216Courtesy of FORD MOTOR CO.
  8. Remove all of the special tools.
  9. Position the drive pinion bearing adjustment shim and the inner pinion bearing on the drive pinion gear stem.
  10. Using the special tools and a suitable press, firmly seat the drive pinion bearing adjustment shim and inner pinion bearing on the drive pinion gear stem.
    Fig 8: Seating Drive Pinion Bearing Using Special Tools
    G03190217Courtesy of FORD MOTOR CO.
    11. CAUTION: Make sure the splines on the drive pinion gear stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth.
    Fig 9: Installing Collapsible Spacer On Drive Pinion Gear
    G03190218Courtesy of FORD MOTOR CO.
  11. Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the pinion stem shoulder.
  12. Install the outer pinion bearing and the drive pinion oil seal slinger.
    Fig 10: Installing Outer Pinion Bearing And Drive Pinion Oil Slinger
    G03190219Courtesy of FORD MOTOR CO.
    13. CAUTION: Installation without the correct tool can result in early drive pinion seal failure.
    CAUTION: If the drive pinion seal becomes misaligned during installation, remove it and install a new drive pinion seal.
    NOTE: Coat the drive pinion seal lips with grease.
    Fig 11: Installing Drive Pinion Seal Using Special Tool
    G03190220Courtesy of FORD MOTOR CO.
  13. Using the special tool, install the new drive pinion seal.
  14. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential housing.
    Fig 12: Installing Drive Pinion Gear In Differential Housing
    G03190221Courtesy of FORD MOTOR CO.
  15. Position the pinion flange.
    1. Lubricate the pinion flange splines with grease.
    2. Position the pinion flange.
    Fig 13: Positioning Pinion Flange
    G03190222Courtesy of FORD MOTOR CO.
  16. Using the special tool, install the pinion flange.
    Fig 14: Installing Pinion Flange Using Special Tool
    G03190223Courtesy of FORD MOTOR CO.
    17. CAUTION: Do not, under any circumstance, loosen the pinion nut to reduce drive pinion bearing preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut.
    CAUTION: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.
    Fig 15: Holding Pinion Flange And Tightening Nut Using Special Tool
    G03190224Courtesy of FORD MOTOR CO.
  17. Use the special tool to hold the pinion flange while tightening the pinion nut.
    • Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench.
  18. Tighten the pinion nut to set the drive pinion bearing preload. Refer to the TORQUE SPECIFICATION  for drive pinion bearings.
    Fig 16: Tightening Pinion Nut
    G03190225Courtesy of FORD MOTOR CO.
  19. Press the left and right differential bearing on the differential assembly.
    1. Position the differential bearing.
    2. Using the special tool, press the differential bearing on the differential assembly.
    Fig 17: Installing Differential Bearing Using Special Tool
    G03190226Courtesy of FORD MOTOR CO.
    20. NOTE: If removed, press the speed sensor ring on with the differential ring gear.
    Fig 18: Pressing Differential Ring Gear
    G03190227Courtesy of FORD MOTOR CO.
  20. Install the differential ring gear.
    1. Place the differential ring gear on the differential assembly.
    2. Hand-start 3 ring gear bolts to align the holes in the differential ring gear and the differential assembly.
    3. Place the differential assembly 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.
  21. Install the ring gear bolts after applying sealer to the bolt threads.
    • Use stud and bearing mount.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 19: Tightening Ring Gear Bolts
    G03190228Courtesy of FORD MOTOR CO.
  22. Install the differential assembly.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential assembly in place.
    Fig 20: Installing Differential Assembly
    G03190229Courtesy of FORD MOTOR CO.
  23. Install a differential bearing shim of the thickness shown on the LH side of the differential case.
    Fig 21: Installing Differential Bearing Shim (LH)
    G03190230Courtesy of FORD MOTOR CO.
    24. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
    Fig 22: Installing Differential Bearing Cap Shim (LH)
    G03190231Courtesy of FORD MOTOR CO.
  24. Install the left bearing cap and loosely install the bearing cap bolts.
    25. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
    Fig 23: Installing Differential Bearing Shim (RH)
    G03190232Courtesy of FORD MOTOR CO.
  25. Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.
  26. Install the right bearing cap and bolts.
  27. Tighten the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 24: Tightening Differential Bearing Cap Bolts
    G03190233Courtesy of FORD MOTOR CO.
  28. Rotate the differential case to make sure it turns freely.
    Fig 25: Rotating Differential Case To Ensure It Turns Freely
    G03190234Courtesy of FORD MOTOR CO.
  29. Install the special tool at the 12 o'clock position.
    Fig 26: Installing Special Tool At 12 O'Clock Position
    G03190235Courtesy of FORD MOTOR CO.
  30. Using the special tools, measure the differential ring gear backlash at 4 equally spaced points.
    1. Attach the special tool.
    2. Position the special tool tip centrally on a drive tooth.
    3. Zero the indicator.
    4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.203 mm (0.008 in) to 0.305 mm (0.012 in) and must not vary more than 0.101 mm (0.004 in) between points measured. A backlash variation of more than 0.101 mm (0.004 in) between points checked indicates gear/case runout.
      • To correct for a high or low backlash, proceed as follows.
    Fig 27: Measuring Differential Ring Gear Backlash Using Special Tools
    G03190236Courtesy of FORD MOTOR CO.
  31. 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 the following tables when adjusting the backlash.
    BACKLASH CHANGE

    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 Shim Size Chart - 4067 - 

    NUMBERS OF STRIPES

    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
  32. Remove the 4 differential bearing cap bolts.
    • Remove the differential assembly.
    Fig 28: Removing Differential Bearing Cap Bolts
    G03190237Courtesy of FORD MOTOR CO.
  33. Measure the thickness of the selected right and left bearing shims.
  34. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 in).
  35. Install the special tools.
    Fig 29: Installing Special Tools
    G03190238Courtesy of FORD MOTOR CO.
    36. CAUTION: Overspreading may damage the differential housing.
    NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final dial indicator reading.
    Fig 30: Removing Special Tools
    G03190239Courtesy of FORD MOTOR CO.
  36. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the screw until spreading the differential housing to the specification.
    3. Remove the special tools.
    37. CAUTION: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, the aluminum housing can be damaged.
    Fig 31: Placing Differential Bearing Shims In Differential Housing
    G03190240Courtesy of FORD MOTOR CO.
  37. Place the differential bearing shims in the differential housing.
  38. Install the differential assembly.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential assembly in place between the differential bearing shims.
    Fig 32: Installing Differential Assembly
    G03190241Courtesy of FORD MOTOR CO.
    39. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.
    Fig 33: Installing Differential Bearing Caps And Bolts
    G03190242Courtesy of FORD MOTOR CO.
  39. Install the differential bearing caps and the differential bearing cap bolts in their original locations and positions.
  40. Loosen and remove the special tool.
    Fig 34: Removing Special Tool
    G03190243Courtesy of FORD MOTOR CO.
  41. Tighten the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 35: Tightening Differential Bearing Cap Bolts
    G03190244Courtesy of FORD MOTOR CO.
  42. Rotate the differential case to make sure it turns freely.
    Fig 36: Rotating Differential Case To Ensure It Turns Freely
    G03190245Courtesy of FORD MOTOR CO.
  43. Install the special tool at the 12 o'clock position.
    Fig 37: Installing Special Tool At 12 O'Clock Position
    G03190246Courtesy of FORD MOTOR CO.
  44. Using the special tools, recheck the ring gear backlash.
    Fig 38: Checking Ring Gear Backlash Using Special Tools
    G03190247Courtesy of FORD MOTOR CO.
  45. Apply marking compound and rotate the differential assembly 5 complete revolutions.
    Fig 39: Rotating Differential Assembly
    G03190248Courtesy of FORD MOTOR CO.
  46. Verify an acceptable pattern check. For additional information, refer to CHECKING TOOTH CONTACT PATTERN AND CONDITION OF THE RING AND PINION .
    47. 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 40: Using Silicone Gasket
    G03190249Courtesy of FORD MOTOR CO.
  47. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.
    • Use silicone gasket and sealant.
  48. Install the differential housing cover.
  49. Fill the axle assembly with the specified lubricant.
  50. Install the rear axle assembly. For additional information, refer to REAR AXLE ASSEMBLY .
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