LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 580 (Rear Drive Axle/Differential-Ford 9.75" Ring Gear) >> In-Vehicle Repair >> Differential Bearings >> Installation

Differential Bearings: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the special tools and the inner and outer drive pinion bearing cups in their respective bores.
    1. Place the special tool on the outer drive pinion bearing cup.
    2. Place the special tool on the inner drive pinion bearing cup.
    3. Install the special tool.
    Fig 1: Positioning Special Tools And Inner And Outer Drive Pinion Bearing Cups In Their Respective Bores
    G02761215Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the drive pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool To Seat Drive Pinion Bearing Cups Into Their Bores
    G02761216Courtesy of FORD MOTOR CO.
    3. CAUTION: Whenever new drive pinion bearings cups are installed, new drive pinion bearings must also be installed.
    NOTE: If a feeler gauge of the specification shown in the illustration can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly seated.
    Fig 3: Checking Drive Pinion Bearing Cups Are Correctly Seated In Their Bores
    G02761217Courtesy of FORD MOTOR CO.
  3. Make sure the drive pinion bearing cups are correctly seated in their bores.
    4. 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 4: Installing Drive Pinion Bearings
    G02761218Courtesy of FORD MOTOR CO.
  4. Install the new drive pinion bearings and special tools as shown.
  5. Tighten the special tool to the specified rotational torque.
    • Tighten to 2.2 Nm (20 lb-in).
    Fig 5: Tightening Special Tool To Specified Rotational Torque
    G02761219Courtesy of FORD MOTOR CO.
    6. NOTE: The gauge block must be offset to obtain an accurate reading.
    Fig 6: Rotating Special Tool Several Half-Turns
    G02761220Courtesy of FORD MOTOR CO.
  6. Rotate the gauge block several half turns to make sure of correct seating of the drive pinion bearings and position the gauge block.
  7. Install the special tool.
    1. Position the special tool.
    2. Install the differential bearing caps.
    3. Install the differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    Fig 7: Installing Special Tool
    G02761221Courtesy of FORD MOTOR CO.
    8. NOTE: Drive pinion bearing adjustment shims must be flat and clean.
    NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between gauge block and gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.
    Fig 8: Identifying Drive Pinion Bearing Adjustment Shim
    G02761222Courtesy of FORD MOTOR CO.
  8. Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
    • The pinion bearing adjustment shim is checked between the gauge block and the gauge tube.
  9. Remove the pinion depth gauge set from the axle housing.
  10. Using the special tools, press the drive pinion bearing and drive pinion bearing adjustment shim until they are firmly seated on the pinion gear.
    Fig 9: Pressing Drive Pinion Bearing And Drive Pinion Bearing Adjustment Shim
    G02761223Courtesy of FORD MOTOR CO.
  11. Place a new drive pinion collapsible spacer on the pinion gear against the pinion gear shoulder.
    Fig 10: Placing Drive Pinion Collapsible Spacer
    G02761224Courtesy of FORD MOTOR CO.
  12. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
    Fig 11: Installing Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
    G02761225Courtesy of FORD MOTOR CO.
  13. Lubricate the new drive pinion seal with grease.
    14. CAUTION: If the new drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal.
    Fig 12: Installing Drive Pinion Seal
    G02761226Courtesy of FORD MOTOR CO.
  14. Using the special tool, install a new drive pinion seal.
  15. Lubricate the pinion flange splines with grease.
  16. Install the pinion gear in the pinion gear bore from inside the axle housing.
    Fig 13: Installing Pinion Gear In Pinion Gear Bore From Inside Axle Housing
    G02761227Courtesy of FORD MOTOR CO.
  17. Using the special tool, install the pinion flange.
    Fig 14: Installing Pinion Flange
    G02761228Courtesy of FORD MOTOR CO.
  18. Position the new pinion nut.
    Fig 15: Positioning Pinion Nut
    G02761229Courtesy of FORD MOTOR CO.
    19. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed.
    CAUTION: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.
    Fig 16: Tightening Pinion Nut
    G02761230Courtesy of FORD MOTOR CO.
  19. Using the special tool to hold the pinion flange, tighten the pinion nut.
    • Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly.
    • Install a Nm (lb-in) torque wrench on the pinion nut.
    • Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the drive pinion bearing preload specification is obtained.
  20. Press the LH and RH differential bearing on the differential assembly.
    Fig 17: Pressing LH And RH Differential Bearing On Differential Assembly
    G02761231Courtesy of FORD MOTOR CO.
  21. Install the differential assembly in the axle housing.
    Fig 18: Installing Differential Assembly In Axle Housing
    G02761232Courtesy of FORD MOTOR CO.
  22. Install a differential bearing shim on the LH side.
    Fig 19: Installing A Differential Bearing Shim On LH Side
    G02761233Courtesy of FORD MOTOR CO.
    23. CAUTION: Index-mark the position of the differential bearing caps as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.
    Fig 20: Installing LH Differential Bearing Cap And Bolts
    G02761234Courtesy of FORD MOTOR CO.
  23. Install the LH differential bearing cap and loosely install the differential bearing cap bolts.
  24. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.
    Fig 21: Installing Progressively Larger Differential Bearing Shims On RH Side
    G02761235Courtesy of FORD MOTOR CO.
  25. Install the RH side differential bearing cap and tighten the LH side and RH side differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 22: Tightening LH Side And RH Side Differential Bearing Cap Bolts
    G02761236Courtesy of FORD MOTOR CO.
  26. Rotate the differential assembly to make sure it rotates freely.
    Fig 23: Checking Differential Assembly Rotates Freely
    G02761237Courtesy of FORD MOTOR CO.
    27. NOTE: If ring gear backlash is within specification, go to  31.
    Fig 24: Measuring Ring Gear Backlash
    G02761238Courtesy of FORD MOTOR CO.
  27. Using the special tools, measure ring gear backlash.
    28. NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.
    Fig 25: Ring Gear Backlash Specification Table
    G02761239Courtesy of FORD MOTOR CO.
    Fig 26: Installing A Thicker Differential Bearing Shim And A Thinner Differential Bearing Shim
    G02761240Courtesy of FORD MOTOR CO.
  28. To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
    • If ring gear backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
  29. Rotate the differential assembly several times to make sure the differential bearings are seated.
    Fig 27: Checking Differential Bearings Are Seated
    G02761241Courtesy of FORD MOTOR CO.
  30. Using the special tools, recheck the ring gear backlash.
    Fig 28: Checking Ring Gear Backlash
    G02761242Courtesy of FORD MOTOR CO.
  31. Remove the differential bearing cap bolts and differential bearing caps.
    Fig 29: Removing Differential Bearing Cap Bolts And Caps
    G02761243Courtesy of FORD MOTOR CO.
    32. NOTE: To establish differential bearing preload, increase both left and right differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.
    Fig 30: Installing Differential Bearing Shims
    G02761244Courtesy of FORD MOTOR CO.
  32. Using the special tool, install the differential bearing shims.
  33. Install the differential bearing caps and differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 31: Installing Differential Bearing Caps And Bolts
    G02761245Courtesy of FORD MOTOR CO.
  34. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  35. Verify an acceptable pattern check.
  36. Install the axle shafts. For additional information, refer to AXLE SHAFT .
    37. CAUTION: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.
  37. Clean the gasket mating surface of the axle and the differential housing cover.
  38. Apply a new, continuous bead of sealant to the differential housing cover.
    Fig 32: Applying Continuous Bead Of Sealant To Differential Housing Cover
    G02761246Courtesy of FORD MOTOR CO.
    39. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured.
    Fig 33: Installing Differential Housing Cover And Bolts
    G02761247Courtesy of FORD MOTOR CO.
  39. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 45 Nm (33 lb-ft).
    40. CAUTION: For Traction-Lok® axles, first fill the axle with 118 ml (4 ounces) of friction modifier.
    NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.
    Fig 34: Identifying Axle Lubricant Fill Level
    G02761248Courtesy of FORD MOTOR CO.
  40. Fill the axle to the level shown with axle lubricant and install the filler plug.
    • Tighten to 30 Nm (22 lb-ft).
  41. Position the driveshaft and align the index mark on the pinion flange.
    Fig 35: Positioning Driveshaft And Align Index Mark On Pinion Flange
    G02761249Courtesy of FORD MOTOR CO.
    42. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.
    Fig 36: Installing Driveshaft Flange Bolts
    G02761250Courtesy of FORD MOTOR CO.
  42. Install the driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
scientia non olet · About LEMON Manuals