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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 644 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- Excursion & F250-F350 Super Duty) >> In-Vehicle Repair >> Differential Bearings >> Installation

Differential Bearings: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the inner and outer bearing cups.
    1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner pinion bearing cup.
    2. Place the special tool on the outer pinion bearing cup.
    3. Install the special tool into the replacer tools.
      Fig 1: Installing Inner And Outer Bearing Cups
      G02769399Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to install the pinion bearing cups into their bores.
    Fig 2: Installing Pinion Bearing Cups Into Bores
    G02769400Courtesy of FORD MOTOR CO.
  3. Make sure the cups are correctly seated in their bores.
    • If a feeler gauge of the specification shown in the illustration 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 3: Inserting Cup And Bottom
      G02769401Courtesy of FORD MOTOR CO.
    4. 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 New Drive Pinion Bearings
    G02769402Courtesy of FORD MOTOR CO.
  4. Assemble and position the special tools.
    PARTS DESCRIPTION

    Item Part Number Description
    1 4621 Pinion bearing (outer)
    2 205-160 Screw (T80T-4020-F43)
    3 4630 Pinion bearing (inner)
    4 205-423 Gauge Disc
    5 205-159 Gauge Block (2.1993-Inch Thick) (T80T-4020-F42)
    6 205-D038 Gauge Tube (4.126-Inch O.D.) (D81T-4020-F51)
    7 205-226 Aligning Adapter (T85T-4020-AH1)
    8 4010 Rear axle housing
    9 205-111 Handle (T76P-4020-A11)
    5. NOTE: This step duplicates final pinion bearing preload.
  5. Tighten the Handle to achieve the pinion bearing preload.
    • Tighten to 2.2 Nm (20 lb-in).
      Fig 5: Tightening Handle To Achieve Pinion Bearing Preload
      G02769403Courtesy of FORD MOTOR CO.
    6. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 6: Rotating Special Tool Several Half-Turns To Make Sure Of Correct Seating Of Pinion Bearings
    G02769404Courtesy of FORD MOTOR CO.
  6. Rotate the special tool several half-turns to make sure of correct seating of the pinion bearings, and position the special tool.
  7. Install the special tool.
    1. Position the special tool.
    2. Install the differential side bearing caps.
    3. Install the differential side bearing cap bolts.
      • Tighten to 119 Nm (88 lb-ft).
        Fig 7: Installing Differential Side Bearing Caps
        G02769405Courtesy 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 shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in the final assembly of integral rear axle assemblies.
  8. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • After the correct shim thickness has been determined, remove the Gauge Tube.
      Fig 8: Adjusting Shim As Gauge For Shim
      G02769406Courtesy of FORD MOTOR CO.
    9. CAUTION: Check the splines on the pinion stem to be sure they are free of burrs. If burrs are evident, remove them by using a fine crocus cloth, working in a rotational motion. Wipe the pinion clean.
    NOTE: The same differential pinion bearing used in the previous procedure must be used in the final assembly of the axle.
    Fig 9: Placing Selected Shim On Pinion
    G02769407Courtesy of FORD MOTOR CO.
  9. Place the selected shim on the pinion and press the bearing until it is firmly seated on the shaft using the special tools.
  10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 10: Placing A New Collapsible Spacer On Pinion Shaft
    G02769408Courtesy of FORD MOTOR CO.
  11. 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
    G02769409Courtesy of FORD MOTOR CO.
  12. Lubricate the new drive pinion seal with grease.
    Fig 12: Lubricating New Drive Pinion Seal With Grease
    G02769410Courtesy of FORD MOTOR CO.
  13. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer.
    Fig 13: Installing Drive Pinion In Drive Pinion Carrier Bore
    G02769411Courtesy of FORD MOTOR CO.
  14. Lubricate the pinion flange splines with grease.
    15. CAUTION: The special tool must be used due to tight spline fit.
    Fig 14: Installing Pinion Flange Using Companion Flange
    G02769412Courtesy of FORD MOTOR CO.
  15. With the drive pinion in place in the axle housing, install the pinion flange using the Companion Flange Replacer.
  16. Position the new pinion nut.
    Fig 15: Positioning New Pinion Nut
    G02769413Courtesy of FORD MOTOR CO.
    17. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed.
  17. Use the special tool to hold the pinion flange while tightening the pinion nut.
    • Refer to the TORQUE SPECIFICATION  for new pinion bearings.
    • Tighten the pinion nut until the desired rotational torque is reached.
      Fig 16: Using Special Tool To Hold Pinion Flange While Tightening Pinion Nut
      G02769414Courtesy of FORD MOTOR CO.
  18. Position the differential case in the rear axle housing.
    • Install a shim on the left side as shown in the illustration.
      Fig 17: Positioning Differential Case In Rear Axle Housing
      G02769415Courtesy of FORD MOTOR CO.
    19. CAUTION: The bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left bearing is seated.
    Fig 18: Installing Left Bearing Cap And Loosely Install Bearing Cap Bolts
    G02769416Courtesy of FORD MOTOR CO.
  19. Install the left bearing cap and loosely install the bearing cap bolts.
  20. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
    Fig 19: Installing Progressively Larger Shims
    G02769417Courtesy of FORD MOTOR CO.
  21. Install the right side bearing cap and tighten the 4 bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 20: Installing Right Side Bearing Cap
      G02769418Courtesy of FORD MOTOR CO.
  22. Rotate the differential case to make sure it rotates freely.
    Fig 21: Rotating Differential Case
    G02769419Courtesy of FORD MOTOR CO.
  23. Using the special tool, measure ring gear backlash.
    • If the backlash is within specification, go to Step  29.
    • If a zero backlash condition occurs, go to Step 24.
    • If the backlash is not within specification, go to Step  25.
      Fig 22: Measuring Ring Gear Backlash
      G02769420Courtesy of FORD MOTOR CO.
  24. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step  37.
    25. NOTE: If 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.
    Fig 23: Installing A Thicker Shim And A Thinner Shim
    G02769421Courtesy of FORD MOTOR CO.
  25. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim as shown.
    • If 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.
      Fig 24: Decreasing Thickness On Other Differential Bearing Shim
      G02769422Courtesy of FORD MOTOR CO.
  26. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 25: Installing Bearing Caps And Bearing Cap
      G02769423Courtesy of FORD MOTOR CO.
  27. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 26: Rotating Differential Several Times To Make Sure Differential Bearings
    G02769424Courtesy of FORD MOTOR CO.
  28. Using the special tool, recheck the backlash.
    Fig 27: Rechecking Backlash
    G02769425Courtesy of FORD MOTOR CO.
  29. Remove the bearing caps and bolts.
    • To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
    • Using the special tool, make sure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 28: Identifying Differential Bearing Shims Are Fully Seated And Assembly
      G02769426Courtesy of FORD MOTOR CO.
  30. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 29: Installing Bearing Caps And Bearing Cap
      G02769427Courtesy of FORD MOTOR CO.
  31. Using the special tool, verify the backlash.
    Fig 30: Using Special Tool Verify Backlash
    G02769428Courtesy of FORD MOTOR CO.
  32. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  33. Verify an acceptable pattern check.
  34. Install the axle shafts. Refer to AXLE SHAFT .
    35. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
  35. Clean the gasket mating surface of the rear axle and the differential housing cover.
  36. Apply a new, continuous bead of silicone sealant to the differential housing cover.
    Fig 31: Apply A New Continuous Bead Of Silicone Sealant To Differential Housing Cover
    G02769429Courtesy of FORD MOTOR CO.
    37. 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 one hour before filling with lubricant to make sure the silicone sealant has correctly cured.
  37. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 45 Nm (33 lb-ft).
      Fig 32: Installing Differential Housing Cover And Differential Housing Cover
      G02769430Courtesy of FORD MOTOR CO.
    38. 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.
  38. Fill the axle to the level shown with axle lubricant and install the filler plug.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 33: Installing Filler Plug
      G02769431Courtesy of FORD MOTOR CO.
  39. Position the driveshaft and align the index mark on the pinion flange.
    Fig 34: Positioning Driveshaft
    G02769432Courtesy of FORD MOTOR CO.
    40. 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.
  40. Install the driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 35: Installing Driveshaft Flange
      G02769433Courtesy of FORD MOTOR CO.
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