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Disassembly And Assembly: Axle: Assembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: To ease installation, coat the seal axle tube mating surfaces with lubricant.
  1. Using the special tools, install the axle shaft oil seals.
    • For model 50 axles, use special tools 205-428, 205-425 (LH), and 205-424 (RH) to install the axle shaft oil seals.
    • For model 60 axles, use special tools 205-428, 205-427 (LH), and 205-426 (RH) to install the axle shaft oil seals.
    • Place the axle shaft oil seals onto the tool, and position the assembly into the differential housing. Lengthen the tool as necessary until both seals start evenly in the axle tubes. Continue to lengthen the tool until both step plates bottom out against the housing.
      Fig 1: Installing Axle Shaft Oil Seals Using Special Tools
      G02769855Courtesy of FORD MOTOR CO.
  2. Place the special tool on the differential case hubs, and position the assembly into the differential housing.
    • For model 50 axles, use special tool 205-D046.
    • For model 60 axles, use special tool 205-D047.
      Fig 2: Placing Special Tool On Differential Case Hubs
      G02769856Courtesy of FORD MOTOR CO.
    3. NOTE: Use a Dial Indicator with a minimum travel capacity of 5.08 mm (0.200 inch).
    NOTE: Repeat this step until there is a consistent reading.
  3. Determine the total thickness of differential bearing shims to install on the differential case hubs, less the preload, which is calculated later in this procedure. Record this measurement as the total case end play.
    1. Position the special tool.
    2. Position the special tool.
      • Locate the tip of the tool on a flat surface of one of the ring gear bolt spot faces.
    3. Force the ring gear as far as possible toward the special tool.
    4. With the pressure still applied, zero the special tool.
    5. Force the ring gear as far as it will go in the opposite direction.
    6. Record the reading.
      Fig 3: Positioning Special Tool
      G02769857Courtesy of FORD MOTOR CO.
      Fig 4: Forcing Ring Gear
      G02769858Courtesy of FORD MOTOR CO.
  4. Remove the differential case with the special tool from the differential housing.
    • Do not remove the special tool from the differential case hubs.
      Fig 5: Removing Differential Case With Special Tool From Differential Housing
      G02769859Courtesy of FORD MOTOR CO.
  5. Install the inner oil baffle and the inner and outer pinion bearing cups.
    1. Position the oil baffle and the bearing cups in the differential housing.
    2. Place the special tools on the inner and outer bearing cups.
      • For model 50 axles, place special tool 205-139 on the outer pinion bearing cup.
      • For model 50 axles, place special tool 205-140 on the inner pinion bearing cup.
      • For model 60 axles, place special tool 205-006 B1 on the outer pinion bearing cup.
      • For model 60 axles, place special tool 205-006 B2 on the inner pinion bearing cup.
    3. Install and tighten special tool 205-098 to seat the cups.
      • Remove the special tools after seating the cups.
        Fig 6: Installing Inner Oil Baffle And Inner And Outer Pinion Bearing Cups
        G02769860Courtesy of FORD MOTOR CO.
        Fig 7: Placing Special Tools On Inner And Outer Bearing Cups
        G02769861Courtesy of FORD MOTOR CO.
    6. 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 8: Identifying Feeler Gauge
    G02769862Courtesy of FORD MOTOR CO.
  6. Check that the cups have seated correctly in their bores.
    7. 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.
  7. Assemble and position the following in the differential housing.
    1. Position the Adapter for 205-S156.
    2. Position the Adapter for 205-S127.
    3. Position the inner pinion bearing.
    4. Position the Adapter for 205-S156 (model 50) or Adapter for 205-S127 (model 60).
    5. Position the Adapter for 205-S156.
    6. Position the outer pinion bearing.
    7. Thread on the Adapter for 205-S127.
      Fig 9: Assembling And Positioning Differential Housing Components (Model 50)
      G02769863Courtesy of FORD MOTOR CO.
      Fig 10: Assembling And Positioning Differential Housing Components (Model 60)
      G02769864Courtesy of FORD MOTOR CO.
    8. NOTE: This step simulates pinion bearing preload.
    Fig 11: Identifying Special Tool Tightening Specification
    G02769865Courtesy of FORD MOTOR CO.
  8. Using a Nm (inch-pound) torque wrench, tighten the special tool to the specification.
    9. NOTE: Offset the special tool to obtain an accurate reading.
    Fig 12: Positioning Special Tool
    G02769866Courtesy of FORD MOTOR CO.
  9. Rotate the special tool several half-turns to seat the pinion bearings. Position the special tool as shown.
  10. Install the special tool.
    1. Position the special tool.
      • For model 50 axles, use tool 205-158.
      • For model 60 axles, use tool 205-D033.
    2. Install the bearing caps.
    3. Install the bolts.
      Fig 13: Installing Special Tool
      G02769867Courtesy of FORD MOTOR CO.
    11. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring device.
    NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.
  11. Using a feeler gauge or flat, clean drive pinion position shims, measure the gap between the special tools. Record the measurement.
    • Remove the special tools after making the correct shim selection.
      Fig 14: Measuring Gap Between Special Tools
      G02769868Courtesy of FORD MOTOR CO.
    12. NOTE: The differential ring gear and pinion is only available in a matched set. Matching numbers etched on both the differential ring gear and pinion are for verification. If installing a new differential ring gear and pinion, verify these numbers match before proceeding with assembly. The end of the pinion with the etched figures is the "button" end.
    NOTE: Use the gear contact pattern method to verify the final pinion position is valid. Refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
  12. Shim the pinion as follows:
    • Etched on the button end of each pinion is a zero (0), or a plus (+) or minus (-) with a number. This number indicates the best running position for each particular differential ring gear. Shimming behind the inner pinion bearing (4630) controls this dimension.
      Fig 15: Locating Pinion Etched Mark
      G02769869Courtesy of FORD MOTOR CO.
  13. If reusing the old differential ring gear and pinion, proceed as follows:
    • Measure and record the old drive pinion position shim thickness and select a new shim of the same dimension.
    • To change the pinion adjustment, drive pinion position shims are available in the thickness shown in the following charts. Measure each shim separately with a micrometer.
      1. Available 
      2. Drive Pinion 
      3. Position Shims 
      4. (Model 50 Axles) 
        DRIVE PINION POSITION SHIMS THICKNESS SPECIFICATION (MODEL 50 AXLES)

        mm Inches
        1.35 0.053
        1.40 0.055
        1.45 0.057
        1.50 0.059
        1.55 0.061
        1.60 0.063
        1.65 0.065
        1.70 0.067
        1.75 0.069
        1.80 0.071
        1.85 0.073
      1. Available 
      2. Drive Pinion 
      3. Position Shims 
      4. (Model 60 Axles) 
        DRIVE PINION POSITION SHIMS THICKNESS SPECIFICATION (MODEL 60 AXLES)

        mm Inches
        1.22 0.048
        1.27 0.050
        1.32 0.052
        1.37 0.054
        1.42 0.056
        1.47 0.058
        1.52 0.060
        1.57 0.062
    14. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  14. If installing a new differential ring gear and pinion, notice the (+) or (-) etching on the new pinion, to select the new shim thickness.
    • For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 inch) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 inch) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 inch) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 inch) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
  15. Using the special tools, install the differential pinion bearing.
    • For model 50 axles, use an axle bearing/seal plate, special tool 205-004, and a suitable press to install the differential pinion bearing.
    • For model 60 axles, use an axle bearing/seal plate, special tool 205-092, and a suitable press to install the differential pinion bearing.
      Fig 16: Installing Differential Pinion Bearing Using Special Tools
      G02769870Courtesy of FORD MOTOR CO.
    16. NOTE: On model 50 axles, position the new collapsible spacer inside the differential housing before installing the pinion bearing and the oil slinger.
    Fig 17: Installing New Collapsible Spacer, Differential Pinion Bearing And Oil Slinger
    G02769871Courtesy of FORD MOTOR CO.
  16. Install the new collapsible spacer (model 50 axles), the differential pinion bearing, and the oil slinger.
  17. Using a suitable driver, install the pinion seal.
    • Lightly coat the pinion seal lip with lubricant.
      Fig 18: Installing Pinion Seal
      G02769872Courtesy of FORD MOTOR CO.
  18. On model 60 axles, install a new collapsible spacer.
    Fig 19: Installing New Collapsible Spacer
    G02769873Courtesy of FORD MOTOR CO.
    19. CAUTION: Do not damage the pinion, the bearings, the seal, or the cup.
    Fig 20: Inserting Pinion
    G02769874Courtesy of FORD MOTOR CO.
  19. Insert the pinion into the differential housing, and seat the inner bearing into the bearing CUD.
    20. 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 while holding the backside of the drive pinion.
    NOTE: If reusing the original pinion and flange, align the index marks made during disassembly.
    Fig 21: Installing Flange Nut
    G02769875Courtesy of FORD MOTOR CO.
  20. Lightly coat the flange splines and seal mating area with lubricant, then install the flange with a new washer and nut.
    21. CAUTION: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.
  21. Tighten the nut.
    • Use the special tool to prevent the flange from turning while tightening the nut. Remove the special tool when taking pinion bearing torque preload readings.
    • Rotate the pinion occasionally to verify that the bearings are seating correctly.
    • Take frequent pinion bearing torque preload readings.
      • If installing new differential pinion bearings, tighten the pinion nut to specifications. Refer to SPECIFICATIONS .
      • If installing the original pinion bearings, the final reading must be 0.56 Nm (5 lb-in) more than the initial reading taken during disassembly.
        Fig 22: Tightening Flange Nut Using Special Tools
        G02769876Courtesy of FORD MOTOR CO.
        Fig 23: Measuring Pinion Bearing Torque Preload
        G02769877Courtesy of FORD MOTOR CO.
  22. Position the differential case with the special tool into the differential housing.
    • For model 50 axles, use special tool 205-D046.
    • For model 60 axles, use special tool 205-D047.
      Fig 24: Positioning Differential Case With Special Tool Into Differential Housing
      G02769878Courtesy of FORD MOTOR CO.
    23. NOTE: Repeat this step until there is a consistent reading.
  23. Determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.
    1. Position the special tool.
    2. Position the special tool.
    3. Force the ring gear into mesh with the pinion.
      • Rock the ring gear to allow the teeth of the gears to mesh.
    4. With the pressure still applied, zero the special tool.
    5. Force the ring gear away from the pinion.
    6. Record the reading.
      Fig 25: Positioning Special Tool
      G02769879Courtesy of FORD MOTOR CO.
      Fig 26: Forcing Ring Gear
      G02769880Courtesy of FORD MOTOR CO.
  24. Remove the differential case with the special tool from the differential housing.
    • Remove the special tool from the differential case.
      Fig 27: Removing Differential Case With Special Tool From Differential Housing
      G02769881Courtesy of FORD MOTOR CO.
  25. Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case. Differential bearing shims are available in the thickness shown in the following chart.
    • For example, a reading of 1.14 mm (0.045 inch), requires that 1.14 mm (0.045 inch) shims be placed on the ring gear side of the differential case.
      1. Available 
      2. Differential 
      3. Bearing 
      4. Shims 
      5. (Model 50 and Model 60 Axles) 
        DIFFERENTIAL BEARING SHIMS THICKNESS SPECIFICATION

        mm Inches
        0.076 0.003
        0.127 0.005
        0.254 0.010
        0.762 0.030
  26. Using the special tool(s), install the differential bearing.
    • For model 50 axles, use special tools 205-D055 and 205-142 to install the differential bearing.
    • For model 60 axles, use special tool 205-D044 to install the differential bearing.
      Fig 28: Installing Differential Bearing Using Special Tools
      G02769882Courtesy of FORD MOTOR CO.
  27. Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
    • Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 inch) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
  28. Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
  29. Using the special tools, install the differential bearing.
    1. Place the special tool under the bearing to protect it during the bearing installation.
      • For model 50 axles, use special tool 205-D016.
      • For model 60 axles, use special tool 205-D018.
    2. Using the special tool(s), install the bearing.
      • For model 50 axles, use special tools 205-D055 and 205-142 to install the differential bearing.
      • For model 60 axles, use special tool 205-D044 to install the differential bearing.
        Fig 29: Installing Differential Bearing Using Special Tools
        G02769883Courtesy of FORD MOTOR CO.
  30. Position the differential bearing cups (4222) on the bearings.
    Fig 30: Positioning Differential Bearing Cups On Bearings
    G02769884Courtesy of FORD MOTOR CO.
    31. CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Do not damage the ring gear and pinion.
  31. Using the special tools, spread the differential housing.
    • Use a soft face hammer to seat the differential into the differential housing.
      • Remove the special tools after seating the differential in the differential housing.
        Fig 31: Spreading Differential Housing Using Special Tools
        G02769885Courtesy of FORD MOTOR CO.
    32. CAUTION: Match the positioning of the mating letters on the bearing caps and the differential housing.
    Fig 32: Installing Bearing Caps
    G02769886Courtesy of FORD MOTOR CO.
  32. Install the bearing caps.
  33. Using the special tools, measure backlash at three equally spaced points.
    • The backlash must be within the specifications, and cannot vary more than 0.05 mm (0.002 in) between points checked. A backlash variation or more than 0.05 mm (0.002 in) indicates gear/case runout.
      • Make the necessary corrections by moving shims from one side of the differential case to the other, until the correct backlash adjustment is achieved.
        • Correct for high backlash by moving the ring gear toward the pinion.
        • Correct for low backlash by moving the ring gear away from the pinion.
          Fig 33: Measuring Backlash Using Special Tools
          G02769887Courtesy of FORD MOTOR CO.
  34. Check the gear tooth contact pattern. Refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
    Fig 34: Identifying Gear Tooth Contact Pattern
    G02769888Courtesy of FORD MOTOR CO.
    35. CAUTION: Clean the differential housing cover mounting surfaces with a suitable solvent, to remove all traces of oil film or foreign material.
    NOTE: The differential housing cover requires the use of silicone sealant material rather than a gasket.
    NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.
    Fig 35: Applying Specified Bead Of Silicone Rubber Sealer
    G02769889Courtesy of FORD MOTOR CO.
  35. Apply the specified bead of silicone rubber sealer as shown.
    36. CAUTION: Allow one hour curing time before filling the axle with lubricant.
    NOTE: Place two cover bolts into the differential housing cover at the 2 o'clock and 8 o'clock positions. This will help to position the differential housing cover onto the differential housing.
    Fig 36: Installing Differential Housing Cover
    G02769890Courtesy of FORD MOTOR CO.
  36. Install the differential housing cover.
  37. Install the axle assembly. Refer to AXLE ASSEMBLY .
  38. Install the axle shaft assemblies and the front wheel hubs. Refer to HUB & WHEEL BEARINGS .
  39. Fill the axle with the specified type and quantity of lubricant.
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