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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 577 (Rear Drive Axle/Differential-DANA 60 & 70) >> Disassembly And Assembly >> Axle Assembly >> Assembly

Axle Assembly: Assembly

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    NOTE: The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case.
    Fig 1: Aligning Tab On Anti-Lock Speed Sensor Ring With Slot In Differential Case
    G02760674Courtesy of FORD MOTOR CO.
  1. Install the anti-lock speed sensor ring if removed.
    • Align the tab in the anti -lock speed sensor ring with the slot in the differential case. Start the two ring gear bolts through the differential case flange into the ring gear to make sure the differential case and the ring gear bolt hole align.
  2. Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
    Fig 2: Pressing Anti-Lock Speed Sensor Ring On Differential Case
    G02760675Courtesy of FORD MOTOR CO.
  3. Apply Threadlock to the new ring gear bolts.
  4. Install and tighten the Grade 9 ring gear bolts alternately and evenly.
    Fig 3: Tightening Grade 9 Ring Gear Bolts
    G02760676Courtesy of FORD MOTOR CO.
  5. Carry out the DIFFERENTIAL CASE END PLAY CHECK .
  6. Position the inner and outer pinion bearing cups and the special tools in their respective differential housing bores.
    1. After placing the inner and outer pinion bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
    2. Place the special tool (outer) on the outer pinion bearing cup.
    3. Install the special tool.
    Fig 4: Placing Special Tool (Outer) On Outer Pinion Bearing Cup
    G02760677Courtesy of FORD MOTOR CO.
  7. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 5: Tightening Special Tool To Seat Pinion Bearing Cups Into Their Bores
    G02760678Courtesy of FORD MOTOR CO.
    8. CAUTION: Always install new pinion bearings when installing new bearing cups.
    NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.
    Fig 6: Checking That Cups Have Seated Correctly In Their Bores
    G02760679Courtesy of FORD MOTOR CO.
  8. Check that the cups have seated correctly in their bores.
    9. CAUTION: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.
    NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.
    Fig 7: Identifying Special Tools - Model 60
    G02760680Courtesy of FORD MOTOR CO.
    Fig 8: Identifying Special Tools - Model 70
    G02760681Courtesy of FORD MOTOR CO.
    Fig 9: Identifying Special Tools - Model 70 HD
    G02760682Courtesy of FORD MOTOR CO.
  9. Assemble and position the following in the differential housing.
    1. Position the special tool.
    2. Position the special tool.
    3. Position the inner pinion bearing.
    4. Position the special tool.
    5. Position the special tool.
    6. Position the outer pinion bearing.
    7. Thread on the special tool.
    10. NOTE: This step simulates pinion bearing preload.
    Fig 10: Tightening Special Tool To Specification
    G02760683Courtesy of FORD MOTOR CO.
  10. Using a Nm (inch-pound) torque wrench, tighten the special tool to specification.
    11. NOTE: Offset the special tool as shown to obtain an accurate reading.
    Fig 11: Rotating Special Tool Several Half-Turns To Seat Pinion Bearings And Position Special Tool
    G02760684Courtesy of FORD MOTOR CO.
  11. Rotate the special tool several half-turns to seat the pinion bearings and position the special tool as shown.
  12. Install the special tool.
    1. Position the special tool.
      • For Model 60/70 axles, use tool 205-D033.
      • For Model 70TR axles, use tool 205-D038.
    2. Install the bearing caps.
    3. Install the bolts.
    Fig 12: Installing Special Tool & Bearing Caps
    G02760685Courtesy of FORD MOTOR CO.
    13. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring devise.
    NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.
    Fig 13: Removing Special Tools After Making Correct Shim Selection
    G02760686Courtesy of FORD MOTOR CO.
  13. Using a feeler gauge or flat, clean drive pinion position shims, measure between the special tools. Record the measurement. Refer to PINION RING GEAR VARIATION NUMBER  for shim selection information.
    • Remove the special tools after making the correct shim selection.
    14. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  14. Install the correct thickness drive pinion position shim on the pinion.
    15. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.
    Fig 14: Installing Pinion Bearing
    G02760687Courtesy of FORD MOTOR CO.
  15. Using the special tool, an axle bearing/seal plate, and a suitable press, install the pinion bearing.
    • For Model 60 axles, use tool 205-092.
    • For Model 70 axles, use tool 205-005.
    16. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload. On Model 70 axles, add the thickness of the pinion preload spacer to the thickness of the old drive pinion bearing preload shims.
  16. Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the following chart.
    AVAILABLE DRIVE PINION BEARING PRELOAD SHIMS

    mm Inches
    0.36 0.014
    0.38 0.015
    0.41 0.016
    0.46 0.018
    0.51 0.020
    0.53 0.021
    0.56 0.022
    0.58 0.023
    0.76 0.030
    17. CAUTION: The pinion preload spacer must always go on the pinion before the drive pinion bearing preload shims.
  17. On Model 70 axles, assemble the pinion preload spacer onto the pinion.
  18. Assemble the drive pinion bearing preload shims onto the pinion, and install the pinion into the differential housing.
  19. Install the outer pinion bearing.
  20. Install the pinion flange.
  21. Use the special tool to prevent the flange from turning while installing the old washer and the lock nut.
    • Tighten the nut to 339 Nm (250 lb-ft).
    Fig 15: Installing Washer And Lock Nut
    G02760688Courtesy of FORD MOTOR CO.
  22. Using an inch-pound torque wrench, rotate the pinion. The torque must read as specified.
    • To increase the preload, remove drive pinion bearing preload shims. To decrease the preload, add shims.
    Fig 16: Rotating Pinion
    G02760689Courtesy of FORD MOTOR CO.
  23. If the pinion bearing preload is within specification, and the pinion position shim has changed, change the drive pinion bearing preload shims by the same amount.
    • The direction arrow pointing toward the pinion flange indicates that by removing the drive pinion position shim, the distance from the centerline of the tubes to the pinion backface increases, giving a plus (+) reading. The drive pinion bearing preload shim pack does not affect the pinion depth setting. However, if the pinion position is changed, the pinion preload will change and may require adjustment to bring the torque-to-rotate within specification. Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload.
    Fig 17: Identifying Arrows On Ring Gear Illustrate Method To Increase Or Decrease Backlash And Differential Bearing Preload
    G02760690Courtesy of FORD MOTOR CO.
  24. With the drive pinion at the correct preload as determined earlier in this procedure, remove and discard the lock nut and the washer. Use the special tool to prevent the flange from turning.
    Fig 18: Removing Lock Nut And Washer
    G02760691Courtesy of FORD MOTOR CO.
  25. Using the special tool, remove the pinion flange.
    Fig 19: Removing Pinion Flange
    G02760692Courtesy of FORD MOTOR CO.
  26. Lubricate the pinion seal rubber lips.
    • Use Premium Rear Axle Lubricant.
  27. Using a suitable driver, install the pinion seal.
    • After installation, verify that the garter spring did not pop out of the seal. If the garter spring popped out, install a new pinion seal.
    Fig 20: Installing Pinion Flange
    G02760693Courtesy of FORD MOTOR CO.
  28. Coat the inside of the pinion flange with a small amount of lubricant.
    • For Model 60/70 axles, use Premium Rear Axle Lubricant.
  29. Install the pinion flange.
    30. CAUTION: Always install a new washer and lock nut.
    Fig 21: Installing Washer And Lock Nut
    G02760694Courtesy of FORD MOTOR CO.
  30. Use the special tool to prevent the flange from turning while installing the new washer and lock nut.
    • Tighten the nut to 339 Nm (250 lb-ft).
  31. Carry out the RING GEAR AND PINION BACKLASH .
  32. Assemble the differential bearing cups to the differential bearings.
    33. CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.
    Fig 22: Spreading Differential Housing To Specified
    G02760695Courtesy of FORD MOTOR CO.
  33. Using the special tools, spread the differential housing to the specification.
    • Use a rawhide hammer to seat the differential into the differential housing pocket.
      • Remove the special tools.
    34. CAUTION: Match the mating letters as noted during disassembly.
    Fig 23: Installing Bearing Caps, Aligning The Letters With Those On The Differential Housing
    G02760696Courtesy of FORD MOTOR CO.
  34. Install the bearing caps, aligning the letters with those on the differential housing. Tighten the bolts to specification.
  35. Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.
    • The backlash tolerance is 0.13-0.203 mm (0.005-0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. A backlash variation of more than 0.05 mm (0.002 inch) indicates gear/case runout.
    • Move the differential ring gear toward the pinion to correct high backlash.
    • Move the differential ring gear away from the pinion to correct low backlash.
    • Moving a specified amount of differential bearing shims from one side of the differential to the other makes these corrections.
    Fig 24: Measuring Differential Ring Gear And Pinion Backlash
    G02760697Courtesy of FORD MOTOR CO.
  36. Confirm the total preload.
    • Using an inch-pound torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential case installed) by the amount shown, with new bearings installed as recommended.
    • If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.
    Fig 25: Measuring Torque Using An Inch-Pound Torque Wrench
    G02760698Courtesy of FORD MOTOR CO.
  37. Carry out the Tooth Contact Pattern Check to verify the final pinion position is correct. For additional information, refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
  38. Install the axle shafts. For additional information, refer to WHEEL HUBS & BEARINGS-FULL FLOATING AXLE-DANA for full-floating axle shafts, or refer to AXLE SHAFT - SEMI-FLOATING AXLE .
    39. CAUTION: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
    CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply sealer to the threads of the original bolts.
    Fig 26: Identifying Bolt Tightening Sequence Of Driveshaft Flange
    G02760699Courtesy of FORD MOTOR CO.
  39. Position the driveshaft flange yoke on the pinion flange with the index marks aligned and install the new bolts.
    40. CAUTION: Clean both flat surfaces (differential housing and differential housing cover) with a suitable solvent to remove all traces of oil film.
    CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.
    NOTE: The differential housing cover uses silicone rubber sealant as a gasket.
    Fig 27: Applying Continuous Bead Of Sealant Of Specified Thickness To Differential Housing Cover
    G02760700Courtesy of FORD MOTOR CO.
  40. Apply a continuous bead of silicone sealant, of the specified thickness, to the differential housing cover.
  41. Place two bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover.
    • Use the two bolts to position the differential housing cover on the differential housing.
  42. Install the remaining bolts. Tighten the bolts alternately and evenly.
    • Tighten Grade 5 bolts to 47 Nm (35 lb-ft).
    • Tighten Grade 8 bolts to 61 Nm (45 lb-ft).
    • Allow 1-hour cure time before filling the axle with the correct amount of specified lubricant.
    Fig 28: Installing Differential Housing Cover Bolts
    G02760701Courtesy of FORD MOTOR CO.
  43. Fill the axle with the specified type and amount of lubricant. For additional information, refer to SPECIFICATIONS .
    44. NOTE: If installed, remove the safety stands from under the frame rails.
  44. Lower the vehicle.
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